Modular Active Grille Shutter Assembly for Scalable Vehicle Platforms

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Solution Overview

Problem

Existing active grille shutter systems have inefficiencies in assembly, shipping density, and adaptability due to being molded as complete parts, which complicates assembly and increases shipping costs, especially when variants are needed.

Innovation Solution

A modular active grille shutter system assembled from vertically and horizontally scalable components using a two-shot molding process to create integrated end caps with rotatable retainers and universal rails, allowing for customizable dimensions and reduced assembly complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the frame is molded as a complete one-piece part, then the structural integrity is improved, but the assembly complexity increases and shipping density decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The frame is divided into multiple separately molded components that can be assembled together. This segmentation allows each component to be manufactured independently with standard molding processes, reducing assembly complexity while maintaining the overall structural integrity through designed connection interfaces between components.

Inventive Principle:

Principle #1Segmentation

2Strength

If the frame is molded as a complete one-piece part, then the structural integrity is improved, but the shipping density decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidshipping density

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

By dividing the frame into multiple smaller components, the shipping density improves as components can be packed more efficiently in shipping containers. The segmentation allows for better space utilization while the components are designed with connection features that ensure proper assembly into the complete frame structure.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If a complete new frame is molded for each variant, then the adaptability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvevariant adaptabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The frame system uses universal base components and modular add-on sections that can be combined in different configurations. This universality allows multiple frame variants to be produced using the same core components, reducing manufacturing costs through economies of scale while maintaining adaptability to meet different application requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The frame is segmented into standardized modular sections that can be selectively assembled to create different variants. This segmentation enables a single base frame design to serve multiple applications by simply adding or removing modular sections, eliminating the need to mold completely new frames for each variant.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If components are distorted during assembly, then the adaptability is improved, but the manufacturing precision decreases

Engineering Contradiction:

Improveassembly flexibilityVSAvoidcomponent precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The frame is divided into multiple separately molded components with standardized connection interfaces. This segmentation allows components to be assembled without distortion by using designed mating features such as recesses, protrusions, or interlocking mechanisms that ensure precise alignment and fit, maintaining manufacturing precision while enabling flexible assembly.

Inventive Principle:

Principle #1Segmentation

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 modular design simplifies assembly, increases shipping density, and accommodates various variants, enabling efficient production and flexible configuration of active grille shutter systems without distorting components, while reducing production costs.

Implementation Method 1

formed using a two shot molding process

Methodology Applied

Scientific EffectTwo-shot molding:

Implementation Method 2

injecting a first shot of molten material through the at least one first shot injection port

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 3

one or more driven retainers each having a vane connection side and an end cap connection side rotatably fixed to the base integrated end cap

Methodology Applied

Scientific EffectRotation:

Data Source

PatentUS10960754B2Mold assembly for active grille shutter system

Publication Date: 2021.03.30 MAGNA EXTERIORS INC

AI summary

An active grille shutter system (AGS) that is assembled from modular components, thereby allowing the AGS to be any desired width or height when assembled. This allows for the creation of different sized AGS for different vehicle platforms, while assembling the AGS from a stock of components that is common to each AGS. The invention is also directed to a method of forming a base integrated end cap with moveable vane retainers and a link arm using a two shot molding process.