Vehicle Engine Cooling Frame Floating Hinge Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle engine cooling module frames face issues with deformation and inefficiency due to flat molding processes, which lead to assembly challenges, material waste, and reduced flap effectiveness, as well as the need for specific molds and presses.
Innovation Solution
A frame design that eliminates the need for specific molds and presses by using pegs to create a floating hinge mechanism, allowing for easier rotation and assembly, with a molding joint plane at the axis of rotation for reinforcement and no joint plane on extensions, enabling smooth surface rotation and control of the flap's opening angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat molding is used to produce the shutter, then the shutter can be manufactured with standard molding processes, but the molding joint plane appears on the extensions causing deformation and reducing rotation effectiveness
Solution Approach 1:
The shutter is divided into two distinct parts: the closure part and the extensions. The closure part is molded separately and then assembled to the extensions via interference fit with pegs. This segmentation allows the closure part to be molded without creating joint planes on the extensions, eliminating the deformation issue while maintaining manufacturability.
Solution Approach 2:
The extensions are extracted from the molding process of the closure part. Instead of molding the entire shutter as one piece, the extensions are formed separately and then attached. This extraction removes the source of the molding joint plane problem from the extensions, allowing them to maintain their required flatness and rotation effectiveness.
2Ease of manufacture
If the shutter is assembled separately on the frame using clips or hinge pins, then the frame and shutter can be manufactured independently, but the assembly process induces deformation and weakens the shutter
Solution Approach 1:
The closure part and extensions are merged into a single integrated shutter component through interference fit assembly. The pegs inserted into the extensions create a strong mechanical connection that combines the two parts into one robust unit, eliminating the need for separate clip or hinge pin assemblies and preventing deformation from multiple assembly steps.
Solution Approach 2:
The extensions are pre-formed with interference fit features (pegs) that are designed to be inserted into the closure part. This preliminary preparation of the connection features allows for a strong, deformation-free assembly that maintains shutter strength while enabling independent manufacturing of the closure part and extensions.
3Productivity
If ejection force is applied during molding, then the shutter can be removed from the mold, but ejection marks appear on the flanks distorting the surface flatness
Solution Approach 1:
The shutter is segmented into the closure part and extensions, with the extensions being attached after molding. This allows the closure part to be molded and ejected efficiently without concern for ejection marks on the extensions, maintaining productivity while ensuring the extensions retain their required surface flatness for effective rotation.
Data Source
Figure 1~2a
Figure 2b
Figure 3~5
AI summary
The frame has a supporting framework (5), and a flap (10) to close entire or portion of an opening of the supporting framework. The supporting framework and the flap are arranged so as to be formed from same molding operation while authorizing the rotation of the flap around a rotation axis (19) between a closed position and an open position. The flap has a closing part and extensions (14a, 14b), where each extension extends laterally from the closing part of the flap in an articulation unit (20) of the flap. The supporting framework and the flap are molded with same material. An independent claim is also included for a method for molding a frame for engine cooling module of motor vehicle.