Active Grille Shutter Hinge Frame With In-Mold Assembly Joints

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Solution Overview

Problem

Current methods for manufacturing movable parts with glass-filled structural plastics, such as active aero grille shutters, are inefficient due to the need for separate molding and assembly of components, which increases labor, equipment, and error rates, and complicates automation by geometrical constraints.

Innovation Solution

An in-mold assembly process that allows for the direct assembly of multiple components, including vane end pivots, drive linkages, and frame end stops, within the molding tooling using dissimilar injection moldable materials that form a weak bond to facilitate breakaway and rotation, reducing the need for post-mold assembly and equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If separate molding and assembly of components is used, then manufacturing flexibility is maintained, but labor intensity and assembly time increase

Engineering Contradiction:

Improveassembly timeVSAvoidassembly process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate molding operations and assembly steps into a single integrated in-mold assembly process. Components are molded and assembled within the same tooling system, eliminating the need for separate post-molding assembly operations. This merging of processes directly reduces assembly time and labor intensity while maintaining manufacturing flexibility through the modular tooling design.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If multiple separate parts are molded and assembled, then component flexibility is maintained, but manufacturing errors and variations increase

Engineering Contradiction:

Improveassembly precisionVSAvoidassembly ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The in-mold assembly system incorporates self-aligning features and self-positioning mechanisms that automatically ensure precise component alignment during the molding process. The tooling design includes built-in guides, locators, and geometric constraints that eliminate the need for manual alignment or complex assembly procedures, thereby improving manufacturing precision while simplifying the manufacturing process.

Inventive Principle:

Principle #25Self-service

3Productivity

If traditional assembly methods are used, then equipment requirements remain standard, but floor space and equipment costs increase

Engineering Contradiction:

Improveassembly efficiencyVSAvoidequipment requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent integrates multiple assembly operations into the molding tooling itself, eliminating the need for separate assembly equipment and fixtures. The in-mold assembly capability is built into the injection molding machine's tooling system, reducing floor space requirements and equipment costs while improving assembly efficiency through the elimination of transfer and handling operations.

Inventive Principle:

Principle #5Merging (Combining)

4Extent of automation

If high operator interface is required for geometric constraints, then assembly precision is maintained, but automation difficulty increases

Engineering Contradiction:

Improveautomation capabilityVSAvoidoperator interface complexity

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system incorporates self-aligning geometric features, such as tapered guides, complementary surfaces, and precision locators, that automatically ensure correct component positioning without requiring operator intervention or complex manual alignment procedures. This enables full automation of the assembly process while maintaining high precision, as the geometry itself performs the alignment function that would otherwise require skilled operators.

Inventive Principle:

Principle #25Self-service

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 process streamlines the assembly of active aero hinge modular frames by integrating components directly from the mold, reducing assembly time, labor, and equipment requirements while enabling efficient torque transmission and rotational joints, thus enhancing manufacturing efficiency and reducing errors.

Implementation Method 1

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

using dissimilar injection moldable materials that form a weak bond to facilitate breakaway and rotation

Methodology Applied

Scientific EffectWeak bond formation: Adhesive

Data Source

PatentUS12017391B2Active aero system in-mold assembly hinge modular frame

Publication Date: 2024.06.25 MAGNA EXTERIORS INC

AI summary

A manufacturing process for an active grille shutter arrangement including in-mold assembly of an active aero hinge modular frame that allows for the joining of multiple components that are to be assembled directly out of the molding process tooling. These components could be the vane end pivots, vane end stops, drive linkages, frame end stops, etc. Final assembly of the system is facilitated by geometrical considerations and molding material considerations in the in-mold assembly (IMA) design.