Press-On Fan Shroud Shield Assembly With Interference Fit Boss
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Solution Overview
Problem
Existing engine cooling fan assemblies face challenges in securely attaching heat/splash shields without complex fastening systems, leading to increased manufacturing and assembly costs, complexity, and reduced durability.
Innovation Solution
A fan shroud assembly with integrally molded bosses and apertures forming an interference fit, allowing deflection for secure attachment of a shield without separate fasteners, utilizing tapered apertures and spring relief slots for a press-on assembly that simplifies tool design and reduces component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex fastening systems are used to attach heat/splash shields, then attachment reliability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the shield and fan shroud into a single integrated assembly where the shield is formed as an integral part of the fan shroud structure. This eliminates the need for separate fastening systems while maintaining attachment reliability through the unified structural design.
Solution Approach 2:
The fan shroud structure serves multiple functions: it provides structural support, houses the cooling fan, and integrates the heat/splash shield function directly into its design. This multi-functionality eliminates the need for separate dedicated shielding components and fastening mechanisms.
2Strength
If separate fasteners are used to secure shields, then attachment strength is improved, but assembly complexity and manufacturing costs increase
Solution Approach 1:
The shield and fan shroud are combined into a single molded structure, eliminating the need for separate fasteners. The attachment strength is achieved through the integral construction where the shield forms part of the fan shroud's structural framework.
Solution Approach 2:
The patent utilizes material property changes during the molding process to achieve secure attachment. The thermoplastic material's ability to be molded and bonded during manufacturing creates strong attachments without requiring separate fastening components or complex assembly operations.
3Reliability
If multiple components are used for shield attachment, then attachment reliability is improved, but recyclability and manufacturing efficiency decrease
Solution Approach 1:
By integrating the shield into the fan shroud as a single molded component, the patent eliminates multiple separate parts and assembly steps. This single-component approach improves assembly efficiency and facilitates recyclability while maintaining attachment reliability through the integrated structural design.
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
This solution enables a robust, cost-effective, and durable attachment method that reduces assembly complexity, manufacturing costs, and improves recyclability, while enhancing protection against debris, liquids, and heat.
Implementation Method 1
The aperture is smaller than the boss such that the aperture receives the boss with an interference fit, causing deflection of the shield, to secure the shield on the fan shroud
Implementation Method 2
at least one slot communicating with the aperture to allow deflection of the shield in a region adjacent the aperture
Data Source
AI summary
A fan shroud assembly (10) includes a fan shroud (14) having a boss (54) formed thereon, and a shield (22) having an aperture (58) and at least one slot (62) communicating with the aperture to allow deflection of the shield in a region adjacent the aperture. The aperture is smaller than the boss such that the aperture receives the boss with an interference fit, causing deflection of the shield, to secure the shield on the fan shroud.