Engine Cover Applique Backing Plate Structural Support
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Solution Overview
Problem
Engine covers, particularly soft ones, face challenges in structural support due to limited attachment points, leading to potential sagging and damage, and existing solutions like over-molding rigid plates are costly and manufacturing-limited.
Innovation Solution
An appliqué with a backing plate that provides structural support and attachment to the engine cover through mounting posts and fasteners, allowing for secure affixation and distribution of support across a sufficient surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If soft engine covers are used to enhance appearance and reduce noise, then aesthetics and noise reduction are improved, but structural support is insufficient leading to sagging and damage
Solution Approach 1:
A rigid backing plate is introduced as an intermediary component between the soft engine cover and the mounting posts. This backing plate provides the necessary structural support and rigidity to prevent sagging and damage, while allowing the soft cover to maintain its aesthetic appearance and noise reduction properties.
Solution Approach 2:
The solution combines soft foam material for the engine cover with a rigid backing plate structure. This composite construction allows each material to perform its optimal function - the soft foam for aesthetics and noise reduction, and the rigid plate for structural support.
2Strength
If rigid plates are over-molded within the foam to support the cover, then structural support is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The support structure is segmented into separate components - the soft engine cover and the rigid backing plate - rather than being integrated through over-molding. This allows each component to be manufactured independently using optimal processes, then assembled together, reducing manufacturing complexity.
Solution Approach 2:
The rigid support plate is extracted as a separate component from the foam cover, rather than being embedded within it through over-molding. This extraction simplifies manufacturing by allowing independent production of each component and reduces tooling requirements.
3Device complexity
If limited attachment points are used on the engine cover, then assembly is simplified, but structural support and reliability are insufficient
Solution Approach 1:
The mounting posts extend through the engine cover in the vertical dimension, allowing the backing plate to be secured from the rear. This three-dimensional mounting approach provides multiple attachment points and broader distribution of support forces, enhancing reliability without complicating assembly.
Data Source
AI summary
An apparatus includes an engine assembly and an engine cover. The engine cover includes at least one through hole extending from a top surface to a bottom surface. An appliqué is mounted on the engine cover. The appliqué includes at least one mounting post extending through the at least one through hole. A backing plate is disposed on a bottom surface of the engine cover receiving the at least one mounting post to secure the appliqué to the engine cover.