Active Grille Actuator Bracket With Fastener-Free Alignment
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Solution Overview
Problem
Current cooling systems for automobiles are inefficient, particularly at start-up, as they remove heat from the engine when it should be brought to operating temperature quickly for fuel efficiency, and they often require multiple fasteners for actuator connection to the grille, leading to aerodynamic inefficiencies and increased labor time.
Innovation Solution
A bracket design that connects multiple pieces without fasteners, using integral attachment and alignment features to support an actuator, simplifying design, tooling, and labor while minimizing components and fasteners, and optimizing airflow for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional actuators are connected to the grille using multiple fasteners, then the connection is secure and reliable, but the device complexity and labor time increase
Solution Approach 1:
The actuator housing is merged with the grille structure by integrating the mounting features directly into the actuator housing itself. The actuator housing serves dual functions: containing the actuator mechanism and providing integrated mounting structures that attach directly to the grille, eliminating the need for separate fasteners and reducing assembly complexity.
Solution Approach 2:
The actuator housing includes self-aligning and self-securing features such as integrated clips, tabs, or snap-fit structures that automatically engage with corresponding features on the grille during installation. This self-service mechanism ensures reliable connection without requiring multiple separate fasteners or complex assembly procedures.
2Reliability
If multiple fasteners are used to connect the actuator to the grille, then the connection is secure, but the labor time and assembly complexity increase
Solution Approach 1:
The mounting system is segmented into integrated modular features within the actuator housing, such as separate clips or tabs that can be independently engaged. This segmentation allows for simplified assembly where each feature can be attached sequentially or simultaneously in a single operation, reducing the time required compared to installing multiple separate fasteners.
Solution Approach 2:
The actuator housing is pre-formed with integrated mounting features during the manufacturing process, such as pre-molded clips, tabs, or attachment structures. This preliminary action ensures that the mounting features are already in place and properly positioned before installation, eliminating the need for additional fastening operations and reducing assembly labor time.
3Reliability
If the bracket includes multiple components and fasteners, then the actuator is securely supported and aligned, but the design complexity and tooling requirements increase
Solution Approach 1:
The support and alignment functions are merged into the actuator housing itself through integrated features such as built-in mounting tabs, alignment ribs, or positioning structures. This consolidation provides secure support and precise alignment while reducing the number of separate components and eliminating the need for additional fasteners.
Solution Approach 2:
The actuator housing serves multiple functions simultaneously: it contains the actuator mechanism, provides structural support, ensures proper alignment, and facilitates attachment to the grille. This multi-functionality is achieved through integrated design features within the housing that combine what would traditionally require separate components.
Data Source
AI summary
A modular a bracket which forms a cavity such that the bracket surrounds and supports an actuator. In one embodiment, the bracket is made of multiple pieces and also connects together without the use of fasteners. The pieces are connected together through the use of several attachment features, with a portion of each of the attachment features integrally formed as part of each half. The bracket also includes a plurality of alignment features integrally formed as part of the bracket. The alignment features support and properly position the actuator within the cavity. The design of the bracket reduces and simplifies design and tooling, and also has minimal components and fasteners, which also simplifies and reduces labor time.