RECONFIGURABLE FRONT AND UPPER ONE PIECE BAFFLES FOR DIRECTING INCOMING AIR FROM A VEHICLE FRONT FASCIA TO A RADIATOR COOLING MODULE
A baffle construction constructed of two or more individual sections, each exhibiting a two part/two shot injection molded material incorporating attachment details for establishing a structurally supporting framework mounting about the vehicle radiator. The baffle sections each include softer interconnecting hinges incorporating the attachment details which assist in creating the structurally self-supporting frame. The assembled baffle defines a four sided box-like structure mounted around a vehicle radiator for directing incoming air through a fascia opening and into a cooling module associated with the radiator.
Latest U.S. Farathane Corporation Patents:
- Method, article and assembly for applying a multi-layer film to an elongate extruded article
- Method for producing a multi shot injection molded article incorporating a heat shield
- Finger tab interface for vehicle pressure relief valve incorporated into a ventilation module for providing slow closing/opening of valve under low pressures resulting from a door slam event
- Injection molded rivet-style fastener and housing with snap assembly functionality along with an injection molding process for producing such a rivet without an undercut feature
- Molded automotive fluid dispensing and manifold distribution system
This Application is a Continuation-in-part of application Ser. No. 13/726,943 filed on Dec. 26, 2012. application Ser. No. 13/726,943 claims the benefit of U.S. Provisional Application 61/585,196 filed on Jan. 10, 2012, the contents of which are incorporated herein in their entirety.
FIELD OF THE INVENTIONThe present invention discloses an improved baffle design for us with a vehicle radiator and cooling module. More specifically, the invention discloses a multi-sided baffle construction which can include individual and inter-assembleable sides or sections, as well as alternatively contemplating a pair of upper and lower interengaging baffles which collectively establish a four sided and structurally supporting enclosure. Another variant contemplates a three sided lower baffle construction with hingedly interconnecting corners, along with a separably attachable top section.
Each individual length is constructed of a two part/two shot injection molded material including an integrally formed harder body section and softer interconnecting hinge components. In a further series of variants, a number of edge located attachment portions are formed at extending edges of each baffle and which, upon configuring the lengths in perpendicular angled fashion relative one another, enable them to be pre-assembled in a shape retaining and structurally supporting fashion prior to installation within the vehicle compartment around the radiator and associated cooling module. The baffles further include reconfigurable portions to facilitate installation to varying sized and dimensioned vehicle fascias, bumper bars, radiators and the like.
DESCRIPTION OF THE RELEVANT ARTThe prior art is documented with examples of various components designed to baffle or direct incoming air, such as through a fascia opening and into a cooling module or the like. These designs have typically consisted of multi-piece assemblies produced by varying manufacturing methods such as vacuum forming, die cutting, injection molding and two shot molding.
With newer vehicles focusing on higher levels of aero-efficiency and enhanced mileage, two-shot component assemblies have become preferred which allow a “touch” condition with the surrounding components to better establish a sealing condition. In use with a conventional vehicle radiator, a three piece design with a main baffle and opposite edge connecting and side extending baffles is also known and which includes the requirement of multiple molds, attachment fasteners or other features, and an attendant difficulty in packaging and shipping, in large part owing to its overall “U” shape.
SUMMARY OF THE PRESENT INVENTIONThe present invention teaches a baffle construction constructed of a two part/two shot injection molded material and which includes an integrally formed body having a first harder panel section and a second softer interconnecting hinge. The two shot material defines a one piece body constructed of a three sided articled including a central body panel and two opposite and interconnected side portions.
The central body panel and side portions each have a specified shape and size and are formed from a first shot harder material including at least an olefinic filled polypropylene. A plurality of living hinges are configured into the body and are located around and between the central panel and interconnected sides. The living hinges each exhibit a specified shape and size formed from a second shot softer material including at least one of a thermoplastic elastomer (TPE) or thermoplastic vulcanite (TPV).
A secondary article is provided and includes an upper baffle assembled along with the lower baffle to define a four sided box-like structure around the radiator. The upper baffle includes individual harder first shot panel portions, between and around which are formed additional softer second shot hinge and pivot locations. At least one of the three sided article and secondary article further incorporate reconfigurable portions to facilitate installation to varying sized and dimensioned vehicle fascias, bumper bars, radiators and the like.
A further variant provides a number of edge located attachment portions which are integrated into edge extending locations of each assembleable baffle. The attachment portions include any of a variety of tab and slot or other configurations which, upon configuring the extending attachment portions in perpendicular angled fashion relative one another, enable them to be pre-assembled in a shape retaining and structurally self-supporting fashion prior to installation within the vehicle compartment around the radiator and associated cooling module.
Advantages of the baffle design include permitting the assembly to be shipped in a single piece lay-flat condition along with their in-molded attachment details, following which the individual baffle profiles are manipulated into position within the engine compartments to acquire its structurally supporting shape. An optional upper baffle can be assembled along with the lower baffle to define a four sided box-like structure around the radiator and likewise includes additional structural details. The upper baffle can likewise include edge extending attachment details for achieving a structurally self-supporting frame configuration about the vehicle radiator. The baffles further include reconfigurable portions to facilitate installation to varying sized and dimensioned vehicle fascias, bumper bars, radiators and the like.
Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:
Referring initially to
As will be further described throughout the several succeeding views, the baffle 10 is constructed of a one piece, three panel and two port foldable/bendable polymeric material and which further provides the ability to easily reconfigure during installation in order to accommodate numerous different vehicle fascia and radiator condenser mount positions. This is further an improvement over prior art baffle designs which require a plurality of individual side pieces which are assembled together at the time of installation and which do not provide a like degree of modifiability in order to reconfigure to fit varying vehicle fascia and radiator designs.
As further depicted in succeeding
A softer interconnecting/boundary defining material 18 is provided by a second shot of softer polymeric material, such as by non-limiting example a thermoplastic elastomer (TPE) or thermoplastic vulcanite (TPV). The softer material is depicted by a plurality of edge trim and interconnecting portions established and around and between the individual harder plasticized panels 12, 14 and 16. For ease and practicality of representation these as shown at 18, 18′, 18″ and are represented by spaced apart flexible trim portions in each of repetitive and reverse indicating fashion for sides 14/12 (FIGS. 2) and 12/16 (
As further depicted, the second shot (softer) material 18, 18′ and 18″ extends along interfaces established between each of the panels 12, 14 and 16 in order to provide inter-flexibility. Additional softer edge trim locations are also defined at 19 (see
The configuration of the three sided baffle is such that it conveniently ships flat in multiple stacked fashion and, given further that it doesn't need to be assembled in multiple pieces, is further capable of being quickly installed by being conformed or bent into a desired shape for surrounding an existing vehicle radiator. As will also be described in additional detail, the template design associated with the edge profiles of the opposite and flexibility connected sides 14 and 16 is further such that, upon being folded upwardly following pre-positioning of the central interconnecting panel 12 underneath the radiator and during installation, the sides are capable of being quickly reconfigured (if need be) and installed to varying dimensioned vehicle fascias and radiator/condenser configurations.
Referring to
As further depicted, the upper baffle 20 is also provided as a single piece and double shot material including harder first shot components 22 and 22′, as well as upper spaced and horizontally extending component 23, around and between which is configured a combined outer perimeter/trim and interior extending second shot (softer) portion 24 for providing the upper baffle with a further measure of flexibility during installation in proximity to and underneath the cooling module 2 (again
During the initial installation sequence, the lower baffle 10 is pressed up onto the lower radiator flange (not shown) by the operator (see opposite and outwardly facing mounting locations 25 associated with the upper baffle 20), while the upper baffle 20 is hung onto the upper condenser flange 5. As with the lower baffle 10, the upper baffle 20 is again shipped flat in multiple stacked fashion, following which it is constructed so that the harder first shot components 22 and 23 (similar to panels 12, 14 and 16 associated with the lower baffle) are again capable of being bent or angularly positioned relative to the softer perimeter and interior extending trim 24.
The present design allows the side wings 26 and 28 to be maintained out of the way while the chassis design is married to the vehicle body within the assembly plant. During installation, the operator rotates additional portions 34 and 36 associated with the sides 14 and 16 of the lower baffle up and onto the radiator end side tanks (not shown) and then fasten them into position.
The flexible two shot baffle design in use assists in providing more aerodynamic efficiency and enhanced mileage of associated vehicle installations by establishing a “touch” condition whereby the two shot component assemblies contact critical locations along the radiator bracketry and upper located cooling module to optimize desired airflow with the surrounding components and thereby establish proper sealing where desired. As previously discussed, the softer second shot material provides living hinge locations to facilitate bending and manipulation of the harder first shot panel locations around, behind and under the radiator and associated vehicle architecture during loading/installation.
As such, the resulting two shot created part requires only one mold for creation and subsequent installation into a variety of vehicle applications. This is further accommodated by designing various template post mold “punch out” locations (see such as previously again shown at 18′ in
Also, and as again previously noted, the ability to produce both the lower and upper baffles 10 and 20 in a substantially flattened profile allows for ease of multiple shipping. As further noted, the lower and upper baffles can be employed separately or in combination in order to tailor the application for optimization of vehicle sealing and aerodynamic airflow.
Referring now to
As will be further described in further detail, and upon pivoting the interconnecting portions of the individual bodies or sections into position and subsequently engaging the attachment portions to one another, the body creates an enclosing and self-supporting framework for installation within the vehicle engine compartment for various under-hood assemblies, such as including active shutter assemblies. The ability to ship the baffle bodies in a lay flat condition, combined with the ability to inter-assemble the bodies into a hinged and structurally self-supporting fashion without the need for additional metal structural supports or brackets, provides both greater functionality and cost savings.
The harder and softer materials can be formed in a two shot molded fashion as previously described and can include the same constructions, such as a harder olefinic filled propylene matched with either of a thermoplastic elastomer or a thermoplastic vulcanite. As shown, the softer trim extending material 56 can extend beyond the hinged locations 58 and 60 into the sides 62/64, such as further incorporating additional harder materials into which are configured inter-attachment portions or details (see for example at 66 and 68 for upper baffle 52) for providing structural self- supporting assembly of the baffle construction, this independent from the engine compartment attachment locations (not shown).
Referring again to
Referring now to
As further shown in
Proceeding to
The lower body 104 (as also depicted in
Additional attachment details are provided, at 134/136 for upper body 102 and 138/140 for lower body 104 (see
Finally,
Having described our invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.
Claims
1. A baffle construction comprising:
- at least two individual bodies each constructed of a two part injection molded material, at least one of said bodies including a harder material incorporated into a panel section and a plurality of second softer materials incorporated into each of a trim extending section and at least one end extending and interconnecting hinge section; and
- a plurality of attachment portions constructed of said harder material and incorporated into each of said bodies, at least a sub-plurality of said attachments being formed into said hinge sections enabling pivoting of said attachments of a selected body into an engaging relationship along with additional attachments associated with another body to create an enclosing and self-supporting framework for installation within a vehicle engine compartment.
2. The baffle construction as described in claim 1, at least one of said bodies further comprising a central panel and two opposite interconnected sides.
3. The baffle construction as described in claim 1, said bodies each having a specified shape and size with said first harder material further comprising at least an olefinic filled polypropylene.
4. The baffle construction as described in claim 2, further comprising a plurality of living hinges located around and between said central panel and said sides.
5. The baffle construction as described in claim 4, said living hinges each having a specified shape and size and being formed from said second softer material including at least one of a thermoplastic elastomer (TPE) or thermoplastic vulcanite (TPV).
6. The baffle construction as described in claim 2, at least another of said bodies further comprising an upper baffle assembled along with said lower baffle to define a four sided box-like structure around the radiator.
7. The baffle construction as described in claim 6, at least one of said bodies incorporating reconfigurable portions which are configured to facilitate installation to any of varying sized and dimensioned vehicle fascias, bumper bars and radiators.
8. A multi-sided and lay flat baffle construction for installation within an engine compartment of a vehicle, comprising:
- at least one multi-sided body including a central panel and opposite interconnected side panels;
- said body constructed of a two part injection molded material including a harder structurally defining material and a softer material, said softer material incorporated into interconnecting hinges between and around said panels; and
- a plurality of attachment portions constructed of said harder material and incorporated into said body, at least a sub-plurality of said attachment portions being formed into said hinge sections enabling pivoting of said body into an enclosure defining configuration, whereupon said attachment portions are inter-engaged to one another to create a self-supporting framework for installation within a vehicle engine compartment.
9. The baffle construction as described in claim 8, said harder material having a specified shape and size and being formed from at least an olefinic filled polypropylene.
10. The baffle construction as described in claim 9, said softer material further comprising a plurality of living hinges located around and between said central panel and said sides.
11. The baffle construction as described in claim 10, said living hinges each having a specified shape and size and being formed from at least one of a thermoplastic elastomer (TPE) or thermoplastic vulcanite (TPV).
12. The baffle construction as described in claim 8, further comprising an upper body assembled along with said multi-sided body to define a four sided box-like structure around the radiator and upper cooling module.
13. The baffle construction as described in claim 12, said upper body further comprising individual harder panel portions, between and around which are formed additional softer hinge and pivot located portions.
14. The baffle construction as described in claim 13, at least one of said bodies incorporating portions which are configurable to facilitate installation to any of varying sized and dimensioned vehicle fascias, bumper bars, and radiators.
15. A multi-sided baffle construction for installation within an engine compartment of a vehicle, comprising:
- a pair of bodies, each including a central panel and opposite interconnected side panels, said bodies being constructed of a two part injection molded material including a first structurally defiling and harder material and a second softer material;
- said softer material defining interconnecting hinges between and around said harder material;
- a plurality of attachment portions constructed of said harder material and incorporated into each of said bodies, at least a sub-plurality of said attachments being formed into said hinge sections enabling pivoting of said attachments into an inter-engaging relationship to create an enclosing and structurally self-supporting framework for installation within a vehicle engine compartment.
16. The baffle construction as described in claim 16, said structurally defining material further comprising an olefinic filled polypropylene.
17. The baffle construction as described in claim 15, said softer material further comprising a plurality of living hinges located around and between said body and side portions.
18. The baffle construction as described in claim 17, said living hinges each having a specified shape and size and being formed from at least one of a thermoplastic elastomer (TPE) or thermoplastic vulcanite (TPV).
19. The baffle construction as described in claim 17, at least one of said bodies incorporating portions which are configurable to facilitate installation to any of varying sized and dimensioned vehicle fascias, bumper bars, and radiators.
20. The baffle construction as described in claim 15, further comprising brackets extending from said structurally self-supporting framework for securing within the engine compartment in order to configure said framework around a radiator.
Type: Application
Filed: Mar 11, 2013
Publication Date: Aug 1, 2013
Applicant: U.S. Farathane Corporation (Auburn Hills, MI)
Inventor: U.S. Farathane Corporation (Auburn Hills, MI)
Application Number: 13/794,028
International Classification: F28F 21/06 (20060101);