Integrally Molded Leaf Screen Seal and Bump Stop
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Solution Overview
Problem
The assembly of air intake seals and hood bump-stops on vehicle hoods is labor-intensive, adds complexity and weight, and negatively impacts fuel economy due to increased parts and operations.
Innovation Solution
A leaf screen with an integrally molded air intake seal and bump-stops, formed from a combination of polymeric and elastomeric materials, where the seal and bump-stops are co-molded onto the leaf screen body using an injection molding process, reducing the need for separate assembly operations and parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seals and bump-stops are assembled separately to the hood and engine compartment, then the air intake sealing and hood flutter prevention functions are achieved, but the labor costs and assembly complexity increase
Solution Approach 1:
The patent combines the seal and bump-stops into a single integrated leaf screen assembly that is molded as one piece. The seal portion extends from the leaf screen body to engage with the hood, while bump-stops are attached to the same assembly, eliminating the need for separate assembly operations and reducing overall complexity.
Solution Approach 2:
The leaf screen assembly serves multiple functions simultaneously: it provides air intake sealing through the seal portion, prevents hood flutter through the bump-stops, and maintains structural support. This multi-functional design consolidates what would otherwise require separate components and assembly steps.
2Reliability
If seals and bump-stops are assembled separately to the hood and engine compartment, then the air intake sealing and hood flutter prevention functions are achieved, but the weight of the vehicle increases
Solution Approach 1:
By merging the seal and bump-stops into a single molded assembly, the patent eliminates redundant mounting hardware, adhesives, and fasteners that would be required if these components were installed separately. This integration reduces the total weight while maintaining both sealing and flutter prevention functions.
3Reliability
If seals and bump-stops are assembled separately to the hood and engine compartment, then the air intake sealing and hood flutter prevention functions are achieved, but the number of parts and assembly complexity increase
Solution Approach 1:
The patent merges multiple functional elements (seal, bump-stops, and leaf screen body) into a single integrated component. This consolidation reduces the number of separate parts from three or more down to one, simplifying both the bill of materials and the assembly process while maintaining all required functions.
4Reliability
If mounting portions are added for seals and bump-stops, then the seal and bump-stop functions are achieved, but the vehicle weight increases
Solution Approach 1:
The seal is integrated directly into the leaf screen body through molded construction, eliminating the need for separate mounting portions, fasteners, or adhesives. The seal portion extends from the body and engages with the hood directly, reducing weight while maintaining reliable engagement.
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 simplifies the assembly process, reduces vehicle weight, and enhances fuel efficiency by integrating the seal and bump-stops directly onto the leaf screen, thereby minimizing labor costs and weight additions.
Implementation Method 1
injecting a polymeric material into a mold to form a body portion. At least one elastomeric material is injected into the mold on a first side of the body portion to form a seal and a plurality of bump-stops. The polymeric material and the elastomeric material are cooled in the mold to solidify and join the polymeric material and the elastomeric material.
Implementation Method 2
The polymeric material and the elastomeric material are cooled in the mold to solidify and join the polymeric material and the elastomeric material.
Data Source
AI summary
A leaf screen for an air intake of an HVAC system of a vehicle having a hood covering an engine compartment. The leaf screen includes a leaf screen body defining an air inlet opening covered by an integrally molded screen. A seal is integrally molded on a top surface of the leaf screen body in front of the air inlet opening. Bump-stops are integrally molded on the top surface that are engaged by an inner panel of the hood when closed. A method of making the leaf screen includes injecting a polymeric material into a mold to form a body portion. At least one elastomeric material is injected into the mold on one side of the body portion to form a seal and a plurality of bump-stops.