Integral Aerofoil Decklid Moulding with Hollow Mandrel
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Solution Overview
Problem
Existing methods for forming automotive components like aerofoils experience sealing issues and aerodynamic drag due to complex connections, and achieve unsightly and difficult-to-manufacture designs.
Innovation Solution
A method and apparatus for forming workpiece components using split mould tooling to create integral, hollow structures where the first and second workpiece structures are connected, allowing for seamless integration of aerofoils with body panels, utilizing a mandrel to form composite materials and ensuring smooth, continuous surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separately formed connectors are used to attach the aerofoil to the decklid region, then the aerofoil can be connected to the vehicle body, but sealing problems occur in the attachment region and aerodynamic drag increases
Solution Approach 1:
The patent merges the aerofoil and decklid into a single integral moulded structure formed simultaneously in one moulding operation. This eliminates separate connectors and attachment regions, thereby eliminating sealing problems and aerodynamic drag caused by joints between separate components.
2Ease of manufacture
If separately formed connectors are used to attach the aerofoil to the decklid region, then the aerofoil can be connected to the vehicle body, but the connections are unsightly and complex
Solution Approach 1:
The patent combines the aerofoil and decklid into a single integral structure that is moulded as one piece. This eliminates the need for separate connectors and assembly steps, simplifying manufacturing while producing a smooth, continuous aesthetic appearance without visible joints or attachments.
3Manufacturing precision
If traditional moulding tooling is used to form hollow structures, then the moulding process can be completed, but the hollow structure cannot be seamlessly integrated with body panels
Solution Approach 1:
The patent divides the moulding tooling into two separate mould parts with a split between them, allowing each part to form one of the opposing surfaces of the hollow structure. This segmentation enables the first mould part to form the body panel while the second mould part forms the hollow structure, which are then seamlessly integrated into a single integral component.
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 approach enables the production of lightweight, aerodynamically optimized components with reduced drag and improved sealing, achieving high-quality finishes that were previously difficult to manufacture.
Implementation Method 1
curing or working the workpiece materials within the mould tooling to form the hollow moulded material workpiece structure
Data Source
AI summary
A decklid (12) for an automobile (10) has an integral aerofoil (24) providing an aero duct (26) between the aerofoil (24) and an upper face section (16) of the decklid (12), the aerofoil (24) being produced hollow using a mandrel (106) to consolidate workpiece material (133) of the (aerofoil 24) inside a void (132) within mould parts (102), (104), the method and apparatus providing the decklid (12) with smoothly merging and continuous A surfaces, as well as smoothly merging B surfaces.