Engine Cooling Module Snap-Fit Assembly for Vibration Resistance
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Solution Overview
Problem
Traditional fastener systems in engine cooling modules are prone to loosening due to vibrations, require additional space and tools for installation, and do not allow for efficient stacking or series assembly of components.
Innovation Solution
A fastenerless attachment system using a radiator, electric fan support, and fan shroud with protruding posts and notches, along with flexible prongs and tabs, that securely connect components without the need for separate fasteners, allowing for easy assembly and preventing lateral and vertical movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fasteners are used, then components can be attached, but separate fasteners must be brought to the parts requiring fastening, adding fastener cost and assembly time
Solution Approach 1:
The attachment features are molded directly into the radiator, fan support, and fan shroud as integral parts of each component. This eliminates the need to separately handle, transport, and install fasteners. The interlocking recesses and protrusions are formed during the molding process itself, reducing assembly to a simple snap-fit operation that significantly reduces assembly time and eliminates fastener costs while maintaining ease of manufacture.
Solution Approach 2:
The components are designed to be self-assembling through their complementary geometric features. The recesses in one component automatically guide and receive the corresponding protrusions from another component during assembly. This self-alignment and self-attachment mechanism eliminates the need for external fasteners and simplifies the assembly process, allowing workers to quickly join components without additional fastening operations.
2Ease of operation
If traditional fasteners are used, then components can be fastened, but in locations with limited installation and removal space, traditional fasteners require space for installation and removal tools as well as space for the person or machine who installs such parts
Solution Approach 1:
The attachment system uses integrated recesses and protrusions that require minimal clearance for assembly. The snap-fit mechanism can be installed by simply pressing the components together, eliminating the need for tool space or extensive worker clearance. This is particularly advantageous in the confined engine bay environment, where the compact interlocking features can be assembled in tight spaces that would be inaccessible to traditional fastening tools and operators.
3Productivity
If traditional fasteners are used, then components can be attached, but traditional fastening devices do not permit stacking or series assembly of multiple parts of a module in a fast, convenient, and reliable manner
Solution Approach 1:
The radiator, fan support, and fan shroud all incorporate the same type of complementary attachment features (recesses and protrusions). This universal attachment system allows any component with these features to be stacked or assembled in series with other components using the same interlocking mechanism. The standardized geometric features enable rapid series assembly of multiple parts without requiring different fastening methods for each component pair, thereby increasing productivity while maintaining simple assembly procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a secure, vibration-resistant connection that eliminates the need for separate fasteners, reduces assembly time and costs, and enables efficient stacking of components, enhancing the reliability and convenience of engine cooling module assembly.
Implementation Method 1
a flexible prong with a protruding tab resides on the radiator next to the upper post. The protruding tab fits over the top plate and prevents the electric fan support from moving off of the lower and upper posts.
Implementation Method 2
The notches in the plates of the fan shroud fit within the second set of notches in the lower and upper posts. Both of the fan support and the fan shroud are prevented from moving laterally off of the lower and upper posts due to the notches
Implementation Method 3
When the fan support is fully pressed into position, the tab on the flexible prong lodges under the tab on the top plate of the fan support when the flexible prong returns to its unbiased position.
Data Source
AI summary
A fastening system fastens a radiator, an electric fan support and a fan shroud as a single unit. The radiator has lower and upper posts to which slotted plates protruding from the fan support and fan shroud fit over. A structural sandwich is formed with the fan support lying between the radiator and the fan shroud. A flexible lever arm with a locking tab lies adjacent to the upper post of the radiator and connects to the radiator. When the fan support is fitted over the posts, the top plate of the electric fan support locks under the first lever arm tab. The fan shroud also has two slotted plates that also fit over the posts of the radiator. The fan shroud locks into place when a lever arm with a tab on the fan shroud locks under a tab that protrudes from the top plate of the fan support.