Flexible Corner Seal for Air Recirculation Baffle
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Solution Overview
Problem
Current recirculation baffle assemblies in the motor vehicle industry are time-consuming and costly due to manual assembly and require additional tooling for fitting different radiators, with inefficiencies in airflow and vibration damping.
Innovation Solution
A recirculation baffle with flexible corners molded in die draw, featuring over-molded flexible material that allows independent movement and adjustment, reducing assembly time and tooling complexity while enhancing airflow efficiency and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the recirculation baffle is assembled manually after molding each piece separately, then the assembly can be created, but the manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple separately molded pieces into a single integrated recirculation baffle component. The molding process now produces one complete assembly with all functional elements (baffle, seal, brackets, reinforcement) formed in a single die-draw operation, eliminating the need for manual assembly of multiple components.
Solution Approach 2:
The patent uses composite construction with a rigid support structure (from the die-draw molded piece) and an integrated flexible seal portion. This composite approach allows the seal to be formed as part of the rigid structure, enabling single-step molding while maintaining both structural integrity and sealing flexibility.
2Adaptability or versatility
If additional tooling is used to adjust the recirculation baffle for different radiators, then the fit can be customized, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates a flexible seal portion that can dynamically adjust to different radiator geometries. The flexible material allows the seal to deform and conform to various shapes without requiring adjustable tooling, providing adaptability through material properties rather than mechanical adjustment mechanisms.
Solution Approach 2:
The patent changes the physical state of the seal material from rigid to flexible, allowing it to adapt to different radiator configurations. This parameter change in material rigidity enables a single tooling design to produce baffles that fit multiple radiator types without requiring additional adjustment tooling.
3Strength
If the recirculation baffle uses rigid corners, then the structural integrity is maintained, but the vibration damping capability is reduced
Solution Approach 1:
The patent creates a composite structure where the rigid support portion maintains structural integrity while the integrated flexible seal portion absorbs vibrations. The flexible material acts as a vibration damper at the corners and connection points, reducing harmful vibration transfer while the rigid portions provide necessary strength.
Solution Approach 2:
The patent applies different material properties to different parts of the baffle: rigid material for the support structure where strength is needed, and flexible material for the seal portions where vibration damping is needed. This local differentiation of material properties optimizes both structural integrity and vibration reduction.
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 flexible corners enable cost-effective manufacturing and packaging, improve airflow efficiency by preventing hot air recirculation, and dampen vibrations, allowing for precise fitting and increased packing density without additional assembly or tooling.
Implementation Method 1
The flexible corners on the recirculation baffle of the present invention provide cost savings in both manufacturing and packaging of the recirculation baffle, as well as provide dampening from vibrations normally transferred from the upper portion to the side portions of the recirculation baffle.
Implementation Method 2
The recirculation baffle creates a seal between the radiator and the vehicle hood. The seal created by the recirculation baffle creates a cooling package of air, in the portion of engine compartment that the radiator draws air from to cool the engine, by preventing the hot air discharged by the fan from recirculating from behind the radiator and through the engine a second time.
Data Source
AI summary
A motor vehicle recirculation baffle including a seal and a plurality of substrates connected to the seal. The seal having an upper portion and two side portions, the two side portions connected to the upper portion by flexible corners. The flexible corners allow the side portions to move independently of each other and independently of the upper portion of the seal. The seal and flexible corners can be molded in die draw. The flexible corners provide a cost savings in the manufacturing of the recirculation baffle, because after the seal is molded.