Radiator Guard Insert Assembly for 3D Metallic Design Features

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for incorporating three-dimensional design structures with metallic surfaces on motor vehicle body parts, especially radiator guards, are complex and limited to convex or rounded surfaces, preventing the use of arbitrary designs, particularly for smaller structures and multiple designs.

Innovation Solution

A two-part component system where a design structure is inserted into a complementary design opening, allowing for precise alignment and varying heights, with the option for metallic finishes, and enabling flexible connection and illumination features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If hot stamping foils are used to create metallic surfaces on three-dimensional structures, then a high-quality appearance is achieved, but the method is limited to convex or rounded surfaces and cannot accommodate arbitrary three-dimensional structures

Engineering Contradiction:

Improvethree-dimensional structure shapeVSAvoiddesign structure versatility

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The body part is divided into a base component and separate design structure elements that can be independently manufactured and then assembled. This segmentation allows arbitrary three-dimensional structures to be created without being constrained by hot stamping limitations, as each element can be precisely formed and then attached to the base component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design structures are integrated into recesses of the base component, with mounting surfaces that receive the design structures from the rear. This nesting approach allows the design structures to be precisely positioned and secured while maintaining their arbitrary three-dimensional forms, resolving the contradiction between shape complexity and design versatility.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If multiple small design structures are incorporated on the body part, then design variety is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvedesign structure varietyVSAvoidmanufacturing structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple small design structures are manufactured as separate elements and then assembled to the base component. This segmentation enables each element to be optimized independently for manufacturing efficiency while allowing great design variety, reducing overall manufacturing complexity compared to creating each structure directly on the body part.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design structures are pre-formed as separate elements with mounting surfaces before being attached to the base component. This preliminary action allows for standardized manufacturing processes and efficient assembly, reducing the complexity that would arise from incorporating multiple small structures directly into the main body part manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If arbitrary three-dimensional structures are created with metallic surfaces, then design freedom is improved, but current hot stamping technology cannot achieve this

Engineering Contradiction:

Improvedesign structure freedomVSAvoidmanufacturing feasibility

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The body part is segmented into a base component and separate design structure elements. This allows arbitrary three-dimensional structures to be manufactured using appropriate processes for each element type, then assembled to the base component. This segmentation makes arbitrary shapes manufacturable while maintaining ease of production through standardized assembly processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design structures are received by recesses in the base component with mounting surfaces that secure them from the rear. This nesting configuration allows arbitrary three-dimensional structures to be easily manufactured as separate elements and then simply attached, greatly improving ease of manufacture while maintaining design freedom.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP4288266B1External body part with design structures and methods of fabrication of inserts

Publication Date: 2026.01.28 MONTAPLAST

Figure 1~2
Figure 3~6
Figure 7

AI summary

The invention relates to an external body part which is designed as an injection-moulded plastic part, in particular a protective cover for a cooler (2), which has at least one design elevation (2b; 12.2) that stands proud of a front-side plane, designed as a three-dimensional structure. In order to be able to also economically provide smaller such design elevations (2b; 12.2), and a multiplicity thereof, with a metallic surface, the invention proposes a two-part construction of the body part, with a front-side painted surface part (2c) with at least one design opening and a rear contact part (2d) which has a design elevation (2b) that, when mounted, protrudes through the design opening.