Abstract: An active grille shutter arrangement having an assembled modular frame with a plurality of primary frame pieces formed by extrusion. Each one of the plurality of primary frame pieces has a first end, a second end and at least one key slot extending between the first end and the second end. Each of the plurality of frame pieces also includes a hollow bore extending through the each one of the plurality of primary frame pieces forming an aperture at the first end and an aperture at the second end. When the modular frame is assembled there is an upper frame portion and lower frame portion, both formed from one of the plurality of primary frame pieces. The arrangement also includes a number of alternate frame and vane pieces that allow several different active grille shapes and configurations to be formed.

Abstract: An active aerodynamic application torque link system including a four bar linkage having a fixed link, driven link, follower link and coupler. The fixed link has a follower link aperture and a driven link aperture. The follower link has a first end rotatably connected to the follower link aperture of the fixed link and a second end of the follower link is connected to the coupler. The driven link is rotatably connected at a first end to the coupler and coupled at a second end to a torque transfer tube that has a cross sectional shape of a four sided polygon with four radial facets. The four sided torque transfer tube is rotatably connected to the driven link aperture of the fixed link. The four bar linkage is used in a number of different applications by connecting the coupler with different components.

Abstract: The present invention is directed to a 4-bar kinematic link component and method for forming the 4-bar kinematic link using a single rotary molding tool. The invention eliminates the need to form individual components of the bracket from several different tools, which will then requires additional assembly steps. The 4-bar kinematic link is formed from two different materials each having a different in mold shrinkage value. This allows for hinge pins to be formed through a base component in a way that will prevent sticking of the components together thereby allowing the parts to have it relative to one another using the hinge pin. The final component is a 4-bar kinematic link that can be used as a 4 bar link mechanism for providing motion.

Abstract: An active aerodynamic application torque link system including a four bar linkage having a fixed link, driven link, follower link and coupler. The fixed link has a follower link aperture and a driven link aperture. The follower link has a first end rotatably connected to the follower link aperture of the fixed link and a second end of the follower link is connected to the coupler. The driven link is rotatably connected at a first end to the coupler and coupled at a second end to a torque transfer tube that has a cross sectional shape of a four sided polygon with four radial facets. The four sided torque transfer tube is rotatably connected to the driven link aperture of the fixed link. The four bar linkage is used in a number of different applications by connecting the coupler with different components.

Abstract: An active aerodynamic application torque link system including a four bar linkage having a fixed link, driven link, follower link and coupler. The fixed link has a follower link aperture and a driven link aperture. The follower link has a first end rotatably connected to the follower link aperture of the fixed link and a second end of the follower link is connected to the coupler. The driven link is rotatably connected at a first end to the coupler and coupled at a second end to a torque transfer tube that has a cross sectional shape of a four sided polygon with four radial facets. The four sided torque transfer tube is rotatably connected to the driven link aperture of the fixed link. The four bar linkage is used in a number of different applications by connecting the coupler with different components.

Abstract: An active aerodynamic application torque link system including a four bar linkage having a fixed link, driven link, follower link and coupler. The fixed link has a follower link aperture and a driven link aperture. The follower link has a first end rotatably connected to the follower link aperture of the fixed link and a second end of the follower link is connected to the coupler. The driven link is rotatably connected at a first end to the coupler and coupled at a second end to a torque transfer tube that has a cross sectional shape of a four sided polygon with four radial facets. The four sided torque transfer tube is rotatably connected to the driven link aperture of the fixed link. The four bar linkage is used in a number of different applications by connecting the coupler with different components.

Abstract: 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.

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.

Abstract: An active grille shutter arrangement having an assembled modular frame with a plurality of primary frame pieces formed by extrusion. Each one of the plurality of primary frame pieces has a first end, a second end and at least one key slot extending between the first end and the second end. Each of the plurality of frame pieces also includes a hollow bore extending through the each one of the plurality of primary frame pieces forming an aperture at the first end and an aperture at the second end. When the modular frame is assembled there is an upper frame portion and lower frame portion, both formed from one of the plurality of primary frame pieces. The arrangement also includes a number of alternate frame and vane pieces that allow several different active grille shapes and configurations to be formed.

Abstract: 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.

Abstract: The present invention is directed to a 4-bar kinematic link component and method for forming the 4-bar kinematic link using a single rotary molding tool. The invention eliminates the need to form individual components of the bracket from several different tools, which will then requires additional assembly steps. The 4-bar kinematic link is formed from two different materials each having a different in mold shrinkage value. This allows for hinge pins to be formed through a base component in a way that will prevent sticking of the components together thereby allowing the parts to have it relative to one another using the hinge pin. The final component is a 4-bar kinematic link that can be used as a 4 bar link mechanism for providing motion.

Abstract: An integrated lamp and fascia system for a vehicle comprises a lamp having a lamp housing. A vehicle fascia includes a fascia pocket defined by two side walls, a bottom wall, and a rear wall, in which the lamp housing is disposed. The rear wall has a fixed portion, a flanged portion, and a cross car hinge seam about which the flanged portion flexes. The lamp housing is mounted to the flanged portion. An adjustment means includes an adjustment clip mounted to the fixed portion of the rear wall to provide a vertical extension thereto, and an adjustment screw accessible from a forward surface of the lamp housing and extending through an upper region of the lamp housing and through the adjustment clip. Turning the screw either moves the upper region of the lamp housing closer to or further from the pocket rear wall by rotating the lamp housing about the hinge seam to adjust vertical aim of the lamp.

Abstract: An integrated lamp and fascia system for a vehicle comprises a lamp having a lamp housing. A vehicle fascia includes a fascia pocket defined by two side walls, a bottom wall, and a rear wall, in which the lamp housing is disposed. The rear wall has a fixed portion, a flanged portion, and a cross car hinge seam about which the flanged portion flexes. The lamp housing is mounted to the flanged portion. An adjustment means includes an adjustment clip mounted to the fixed portion of the rear wall to provide a vertical extension thereto, and an adjustment screw accessible from a forward surface of the lamp housing and extending through an upper region of the lamp housing and through the adjustment clip. Turning the screw either moves the upper region of the lamp housing closer to or further from the pocket rear wall by rotating the lamp housing about the hinge seam to adjust vertical aim of the lamp.