Plastic Hood Module with Metal Bearing Bracket
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Solution Overview
Problem
Existing hood modules for internal combustion engines face challenges in being lightweight, easy to assemble, and noise-dampening while minimizing alignment and machining processes, especially during large-scale production of hybrid cylinder head covers, where thermoplastic covers need to be impermeable and securely fastened without additional material weight.
Innovation Solution
A hood module design featuring a precisely positioned metal bearing bracket connected to a plastic hood body via joint elements, allowing for easy alignment and fixation without overmolding, using sleeve-shaped or pin-like joining elements that melt into the plastic to create a secure, form-fitting connection, enabling minimal weight and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bearing bridges are completely encased in plastic cover body, then alignment precision is improved, but plastic material proportion and weight increase
Solution Approach 1:
The bearing bridges are nested within the plastic hood body structure, with the plastic material forming the outer housing that contains and positions the metal bearing bridges. This nesting arrangement provides precise alignment through the integrated structure while minimizing the volume of plastic material required, thereby reducing overall weight compared to complete encasement.
2Adaptability or versatility
If bearing bridges are pre-fixed using screws in plastic housing, then alignment freedom is improved, but handling complexity and assembly time increase
Solution Approach 1:
The bearing bridges are pre-positioned and fixed to the plastic hood body during the injection molding process itself, rather than requiring separate post-assembly steps. The injection molding operation simultaneously forms the plastic housing and secures the bearing bridges in their correct positions, eliminating subsequent alignment and fastening operations.
3Adaptability or versatility
If bearing bridges are made free to move until mounting, then alignment flexibility is improved, but assembly precision and reliability decrease
Solution Approach 1:
The bearing bridges are pre-positioned and fixed to the plastic hood body during the injection molding process itself, rather than requiring separate post-assembly steps. The injection molding operation simultaneously forms the plastic housing and secures the bearing bridges in their correct positions, eliminating subsequent alignment and fastening operations.
4Productivity
If thermoplastic covers are joined to bearing bridges in short cycle times, then productivity is improved, but sealing reliability and impermeability may worsen
Solution Approach 1:
The joining of the thermoplastic cover to the bearing bridges is merged with the injection molding process itself. The bearing bridges are positioned in the mold, and the plastic material is injected to simultaneously form the cover and create the joint connections, completing both operations in a single cycle without separate joining steps.
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 design results in a lightweight, cost-effective, and easily assembled hood module with enhanced noise damping, allowing for precise alignment and secure fastening of bearing brackets to the cylinder head, reducing the need for complex alignment processes and minimizing material usage.
Implementation Method 1
the joining element is heated, forming a melting zone in the plastic material
Implementation Method 2
forming a melting zone in the plastic material
Data Source
Figure 1
Figure 2
Figure 3~4d
AI summary
The invention relates to a hood module (1) for arranging on a cylinder head of an internal combustion engine, said module comprising a hood body (10) consisting of plastic and also comprising at least one bearing bracket (11) having a metal material for rotatably receiving at least one camshaft (12) in the hood module (1). According to the invention, the bearing bracket (11) is arranged in a precise position on the hood body (10) by means of a joint connection (13), such that the bearing bracket (11) is aligned for arrangement on the cylinder head by means of the hood body (10).