Active aero system in-mold assembly hinge modular frame
AssigneeMagna Exteriors Inc.
InventorsBraendon Lindberg, Ross J. Parpart, Anthony J. Povinelli
Life of this patent
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Abstract
A manufacturing process for an active grille shutter arrangement including in-mold assembly of an active aero hinge modular frame that allows for the joining of multiple components that are to be assembled directly out of the molding process tooling. These components could be the vane end pivots, vane end stops, drive linkages, frame end stops, etc. Final assembly of the system is facilitated by geometrical considerations and molding material considerations in the in-mold assembly (IMA) design.
Claims20
A process for manufacturing in-mold assembly of a hinge modular frame, comprising:
- providing a first material that is injection moldable;
- providing a second material that is injection moldable material, said second material is different from the first material;
- providing a two shot molding tool having a first molding cavity for forming at least one first body portion of a hinged assembly;
- providing a second molding cavity for forming a cooperating at least one second body portion which molds at an edge break contact with the first body portion of said hinged assembly;
- injecting said first material into the first molding cavity to form said first body portion;
- injecting said second material into said second molding cavity to form said at least one second body portion, wherein the first material is the edge of the second material and is operable to form an edge break contact surface having an effectively weaker bond and predetermined break away geometry.
A process for manufacturing an active aero system, comprising:
- providing a first material that is injection moldable;
- providing a second material that is injection moldable material, said second material is different from said first material;
- providing a two shot molding tool having a first molding cavity for forming at least one first body portion of a hinged assembly;
- providing a second molding cavity for forming a cooperating at least one second body portion which molds at an edge break contact with the first body portion of said hinged assembly;
- in-mold assembly of a hinge modular frame including injecting said first material into the first molding cavity to form said first body portion and injecting said second material into said second molding cavity adjacent to said first material forming an edge break contact surface having an effectively weaker bond and predetermined break away geometry;
- moving said first and second body portions to said nesting assembly and pressing the first and second body portions together to break the weaker bond between said first and second body portions and assemble said first and second body portions together forming an assembled part, wherein said at least one second body portion rotates relative to said first body portion in said assembled part.
A method of in-mold assembly of an active aero system, comprising:
- providing a rotary tool operable for forming predetermined geometrical features at a plurality of rotational joints;
- providing at least one first shot of molten material forming at least one first portion;
- providing at least one second shot of molten material that is a different material than the first shot, forming a plurality of second body portions, said first and second shot of molten materials coming into contact and forming a boundary having predetermined edge break geometry at the boundary of each of said first body portion and plurality of second portions;
- pressing said first body portion and said plurality of second body portions together forming a single component.
Dependencies are inferred from the claim text.