Mold assembly for active grille shutter system

An active grille shutter system assembled from modular components comprising:

• a base integrated end cap having a first female key at a first end and a second female key at a second end, 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, a drive retainer with a vane connection side and an end cap connection side rotatably fixed to the base integrated end cap;
• a driven retainer end cap extension having a male key at a first end and a female key at a second end, one or more driven retainers having a vane connection side and an end cap connection side rotatably fixed to the driven retainer end cap extension, wherein the male key of the driven retainer end cap extension is connectable to the second female key of the base integrated end cap;
• a link arm connected to and extending between each of the one or more driven retainers and the drive retainer.
• a base non-integrated end cap having a first female key at a first end and a second female key at a second end, a plurality of posts equal to both the number of one or more driven retainers and the drive retainer located on the base integrated end cap,
• a post end cap first extension having a male key at a first end and a female key at a second end, one or more posts equal to the number of one or more driven retainers of the driven retainer end cap extension, wherein the male key of the post end cap extension connects to the second female key of the base non-integrated end cap;
• a plurality of sets of universal rails each having a first end with a male key shape and a second end with a male key shape, where a first set of the plurality of sets of universal rails has a length that is shorter than all other plurality of sets of universal rails and a second set of the plurality of sets of universal rails has a length that is larger than all the other plurality of sets of universal rails, wherein one selected set of universal rails of the plurality of sets of universal rails has a first universal rail connected to the first female key of the first end of the base integrated end cap using the male key on the first end of the first universal rail and the second end of the first universal rail is connected using the male key on the second end to the first female key of the first end of the base non-integrated end cap, thereby forming a bottom side of the modular frame, and a second universal rail of the selected set of universal rails is connected to the female key of the driven retainer end cap extension and the female key of the post end cap extension, thereby forming a top side of the modular frame;
• a plurality of sets of base vanes, a number of individual base vanes in each of the plurality of sets of base vanes is equivalent to the total number of one or more driven retainers of the base integrated end cap plus the drive retainer, wherein each individual base vane of the plurality of sets of base vanes has a first end and a second end, wherein a first set of the plurality of sets of base vanes has a length that is shorter than all other plurality of sets of base vanes and a second set of the plurality of sets of base vanes has a length that is larger than all the other plurality of sets of vanes, wherein one selected set of base vanes of the plurality of sets of vanes is connected between one selected from the group including the base integrated end cap and the base non-integrated end cap;
• and
• a plurality of sets of extension vanes, the number of extension vanes in each of the plurality of sets of extension vanes is equivalent to the total number of one or more driven retainers the driven retainer end cap extension, wherein each extension vane of the plurality of sets of extension vanes has a first end and a second end, wherein a first set of the plurality of sets of extension vanes has a length that is shorter than all other plurality of sets of extension vanes and a second set of the plurality of sets of extension vanes has a length that is larger than all the other plurality of sets of extension vanes, wherein one selected set of extension vanes of the plurality of sets of extension vanes is connected between on selected from the group including the driven retainer end cap extension and the post end cap extension.

A method of in mold forming an integrated end cap assembly for use on an active grille shutter system comprising the steps of:

• providing a first mold cavity with an integrated end cap body forming surface and a link arm forming surface by using a first platen, a second platen and a third platen to form the integrated end cap body forming surface and the third platen and a link arm platen that close form the link arm forming surface;
• providing a mold cavity with an integrated end cap body forming surface and a link arm forming surface by using a first platen and a second platen to form the integrated end cap body forming surface and a third platen and a link arm platen that close form the link arm forming surface;
• providing at least one first shot injection port connected to the link arm forming surface and the integrated end cap retainer forming surface;
• injecting a first shot of molten material through the at least one first shot injection port into the link arm forming surface and the integrated end cap body forming surface and forming a link arm and an integrated end cap body;
• changing the first mold cavity and providing a second mold cavity with at least one vane retainer forming surface formed from the integrated end cap body, the link arm, a vane retainer platen and a spacer positioned between the link arm and the integrated end cap body;
• changing the mold cavity and providing at least one vane retainer forming surface formed from the integrated end cap body, the link arm, a vane retainer platen and a spacer positioned between the link arm and the integrated end cap body;
• providing at least one second shot injection port connected to the at least one vane retainer forming surface;
• injecting a second shot of molten material through the at least one second shot injection port into the at least one vane retainer forming surface and forming at least one vane retainer using the link arm and the integrated end cap body as portions of the retainer forming surface, and
• opening the cavity and removing the integrated end cap assembly.