Radiator Mounting Using Wire Form and Molded Features
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Solution Overview
Problem
Current radiator mounting arrangements for off-road utility vehicles are costly and require a high number of parts and complex assembly processes, making them inefficient for cost reduction and time-saving.
Innovation Solution
A radiator mounting arrangement using a wire form fastened to a utility vehicle frame, with integrally molded features on the radiator's top tank that secure the radiator without separate fasteners, allowing for easy assembly and flexibility to accommodate thermal expansion and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sheet metal brackets with threaded fasteners and resilient foam are used, then the radiator is securely mounted, but the cost and parts count increase
Solution Approach 1:
The wire form integrates multiple functions into a single component: it serves as both the mounting bracket and the fastening mechanism, eliminating the need for separate sheet metal brackets, threaded fasteners, and resilient foam layers. The wire form is bent into a configuration that simultaneously provides structural support and secure attachment to the radiator tank.
Solution Approach 2:
The wire form is designed to perform multiple functions: it acts as a structural bracket, a fastening element, a vibration dampener, and a thermal barrier. This multi-functional design replaces traditional multi-component mounting systems, reducing parts count while maintaining mounting security.
2Reliability
If traditional sheet metal brackets with threaded fasteners are used, then the radiator is securely mounted, but the assembly time increases
Solution Approach 1:
The wire form is pre-bent into its final configuration during manufacturing, with all necessary bends and shapes already in place. This preliminary shaping eliminates the need for on-site bending, cutting, or assembly operations, allowing the component to be installed as a complete unit and significantly reducing assembly time.
Solution Approach 2:
The wire form's geometry is designed to self-secure to the radiator tank through its bent configuration, eliminating the need for separate fastening operations. The component serves itself by incorporating its own attachment mechanism into its structure, requiring no additional fasteners or assembly steps.
3Device complexity
If integrally molded features are used on the radiator tank, then separate fasteners are eliminated, but manufacturing complexity increases
Solution Approach 1:
The mounting features are integrated directly into the radiator tank's molding process, combining the tank fabrication and mounting feature creation into a single manufacturing step. This eliminates the need for separate fasteners and reduces assembly operations, as the mounting features are already present on the tank when it is produced.
Solution Approach 2:
The integrally molded features serve dual purposes: they maintain the structural integrity of the radiator tank while simultaneously providing attachment points for the wire form. This multi-functionality eliminates the need for separate fasteners, as the molded features themselves perform the fastening function.
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 solution significantly reduces the cost, parts count, and assembly time required for mounting radiators, providing a secure and efficient mounting system that adapts to movements and thermal changes.
Implementation Method 1
The wire form is fastened to a frame member of a utility vehicle, having a plurality of integrally molded features in a top tank of a radiator, with the wire form held between the integrally molded features without separate fasteners
Data Source
AI summary
A radiator mounting arrangement on a utility vehicle with an injection molded top tank and bottom tank, the top tank having a plurality of integrally molded features extending upwardly therefrom. A wire form is attached to a frame member of the utility vehicle and engages the integrally molded features without fasteners.