FR2947303A1 - Fan shroud for motor vehicle, has shutter swiveling to control passage of air flow through air passage opening, where shutter is connected to wall by flexible hinge, which is connected to face of wall by molding - Google Patents

Abstract

The shroud (10) has a wall (12) molded and provided with an air passage opening (30) for passage of air flow. An assembled shutter (32) swivels around a horizontal axis to control the passage of air flow through the air passage opening. The shutter is connected to the wall by a flexible hinge (34), which is connected to a face of the wall by molding. The wall is provided with an edge that is shifted slightly downward with respect to the air passage opening. The air passage opening is provided in a rectangular form. An independent claim is also included for a method for manufacturing a fan shroud.

Description

TECHNICAL FIELD The invention relates to motor vehicle equipment.

It relates more particularly to a fan nozzle 10 comprising a molded wall, for example made of polymer, such as, in particular, plastic material, and provided with at least one opening for the passage of an air flow, as well as a flap pivotally mounted to control the flow of air through the opening. A motor vehicle usually comprises a cooling module consisting of one or more heat exchangers, namely the engine cooling radiator and, if appropriate, an air conditioning condenser, a charge air cooler, etc. . This cooling module is designed to be traversed by an air flow under the action of at least one fan and / or the speed of the vehicle.

The fan nozzle is placed either in front of or behind the cooling module, with reference to the direction of travel of the motor vehicle.

The fan nozzle is conventionally formed of a molded plastic wall which has one or more circular apertures each receiving a helix forming part of a motor-fan unit to force the passage of the air flow through the fan module. cooling.

It is also known to provide the fan nozzle with one or more air passage openings each provided with a pivotally mounted flap to control the flow of air through the opening.

When the vehicle is traveling at high speed, and the fan motor unit is not powered, this flap opens automatically to ensure the flow of air. On the other hand, when the vehicle is stopped or moving at low speed, and the fan motor unit is running, the shutter is usually closed.

Thus, these shutters open at high speed of the vehicle due to the dynamic pressure exerted by the air and close by gravity and depression when the GMV is powered at low vehicle speed.

Until now, these flaps are added to the nozzle after molding. They are then assembled mechanically by a mechanical hinge which is snapped onto the flap and the nozzle after molding thereof. This results in the necessity of providing a manual assembly operation at the outlet of the molding press of the fan nozzle.

The main purpose of the invention is to simplify this assembly by eliminating all investments related to the molding of shutters (mold and injection molding machine) and their assemblies (assembly stations, control stations, etc.).

The invention proposes for this purpose a fan nozzle of the type defined in introduction, wherein the flap is connected to the wall by at least one flexible hinge, for example polymer, such as, in particular, plastic and / or elastomer which is overmolded at least to one side of the wall.

In one embodiment, the shutter is integrally molded with the wall and the hinge is also overmolded to one side of the shutter. According to another embodiment, the hinge is made from the component material, the hinge and shutter assembly being then overmolded to said wall face by said hinge.

Thus, the conventional mechanical hinge is replaced by a flexible hinge which is overmolded to the wall of the fan nozzle, see the shutter, overmolding operation that can be performed directly in the manufacturing mold. This results in a simplification of manufacture.

In the present description, when speaking of a component, it goes without saying that this applies to one or more components, each component being able to control an opening of air passage, and being connected each time to the wall of the fan nozzle by at least one flexible hinge.

According to a particular embodiment, the fan nozzle is provided with seals, provided, for example, at the level of the shutter (s) and / or the wall of the nozzle, to be able to block the passage of air to the periphery of said openings when the shutter or flaps are in the closed position.

In another aspect, the invention relates to a method for manufacturing a fan nozzle as defined above, this method comprising the following operations: a) providing a mold capable of molding the wall and the shutter; b) performing a first step of injecting a polymer, especially a plastic material, into the mold to mold the wall; c) performing a second step of injecting a polymer, in particular a material plastic and / or elastomer, in the mold for overmolding at least one flexible hinge on the wall; and d) unmolding the wall which carries with it the flap and the hinge.

According to a first embodiment, the flap is also made by the first injection step, the flap being housed in the air passage opening. And the hinge is overmolded to the flap during the second injection step. According to another embodiment, the flap is made by the second injection step, the flap being housed in the air passage opening.

According to a preferred example, associated with the embodiment where the wall and the shutter are made during said first injection step, this method comprises the following operations:

a) providing a first mold part and a second mold part, movable between a close position and a remote position by delimiting, in the close position, a mold cavity for the wall and a mold cavity for the shutter;

b) performing said first injection step by simultaneously injecting a polymer into the two molding cavities; c) performing said second injection step by injecting a polymer into a portion of the two cavities, previously closed; and d) moving the first mold portion and the second mold portion to the remote position to effect joint release from the wall, flap and flexible hinge.

Advantageously, in the first injection step, the polymer is also injected into communication passages connecting the two molding cavities, which makes it possible to create material bridges between the wall and the shutter and, in the operation of ), the material bridges are broken by the relative displacement of the first mold part and the second mold part.

Advantageously, in the first injection step, the flap is molded in a position corresponding substantially to a closed position of the air passage opening.

In the description which follows, made only by way of example, reference is made to the accompanying drawings, in which: FIG. 1 is a perspective view of a fan nozzle equipped with two motor-fan units and three shutters made; according to the invention, the flaps being in the closed position; - Figure 2 is a view similar to Figure 1 in which the flaps are in the open position;

- Figure 3 is a partial sectional view of the fan nozzle and a shutter during molding, the shutter 30 being in a substantially closed position;

- Figure 4 is a view similar to Figure 3 in a closed position of the flap, when the fan motor unit is in operation; - Figure 5 is a view similar to Figure 4 in an open position of the flap allowing an air passage, when the vehicle is traveling at high speed; FIGS. 6A to 6D are sectional views of a manufacturing mold intended for molding the fan nozzle and the shutter and for overmolding the flexible hinge, in several successive phases of the molding operation; and FIGS. 7A to 7C are views similar to FIGS. 6B to 6D in an alternative embodiment of the production mold.

FIGS. 1 and 2 show a fan nozzle 10 intended to be placed, in this embodiment, behind a cooling module (not shown) of a motor vehicle, reference being made to the direction of advancement of the vehicle (forward). The cooling module mainly comprises an engine cooling radiator and one or more other heat exchangers, the entire module being traversed by the same air flow.

The fan nozzle 10 comprises a molded wall 12. This may be, in particular, a polymer wall, for example a rigid plastic material. A suitable material is a polyamide, in particular PA 6 filled with glass, for example glass fibers. It may also be polypropylene loaded with glass.

The wall 12 has a generally rectangular shape and. it is surrounded by a frame 14 provided with fixing lugs 16 for attaching the fan nozzle to the cooling module (not shown). This wall 12 is rigid enough to allow the support of accessories or equipment.

In the example shown, the wall 12 is provided with a first main opening 18 of circular shape for housing a propeller 20 of a motor-fan unit 22. It further comprises another main opening 24 of circular shape, but of smaller diameter than the main opening 18. This main opening 24 is intended to accommodate a propeller 26 of a motor-fan unit 28.

Through the wall 12, and above the opening 24, are provided three air passage openings 30 each having a rectangular shape, the long sides of the rectangle being arranged in a horizontal position. These openings are superimposed in the vertical direction and they are controlled by three respective flaps 32 also of rectangular shape. In the illustrated embodiment, each of the flaps 32 is integrally molded with the wall, i.e. it is molded together with the wall 12 in a single operation.

These flaps are connected to the wall by at least one flexible hinge, here two flexible hinges 34 made of plastic and / or elastomer. It may be, for example, rubber.

According to the invention, each of the flexible hinges 34 is overmoulded on the one hand to a face of the wall 12 and, in the present embodiment, to one side of the flap 32, on the other hand. In the case of Figure 1, the flaps 32 are in the closed position and prevent the passage of air, when the two motor fan units 22 and 28 are in operation.

In the case of Figure 2, the flaps 32 are open, which allows air to pass through the openings when the vehicle is traveling at high speed, the motor-fan units may be in operation or stopped according to the cooling power needed. The flaps are opened automatically under the effect of the dynamic pressure exerted by the air flow.

The flaps 32 thus rotate, freely, each time around a horizontal axis, without it being necessary to provide an actuator or other means for pivoting them from the closed position to the open position, and vice versa. .

Reference is now made to FIG. 3 which shows part of the wall 12 and the flap 32 in the molding position. The wall 12 extends, above the opening 30, by a flange 36 which has a face 38 on which is overmolded by a part of the flexible hinge 34. Another part of the flexible hinge 34 is linked by overmolding on one side 40 of the shutter. Below the opening 30, the wall 12 has another flange 42 which also protrudes by being offset slightly downwards with respect to the opening 30 to thereby form a stop 45 for the flap in the closed position. In the case of Figure 3, the flap is in its molding position, that is to say, it is slightly ajar, without coming into contact with the stop 45.

The flap 32 has an upper edge 44 which has molded with the rim 36, that is to say that the flap 32 is molded at the same time as the wall 12 in the same mold. The flap 32 has a lower edge 46 which is made without contact with the abutment 45 and the flange 42.

Injection of the rigid plastic material takes place in the region of the upper edge 44, so that the flap 32 is connected to the flange 36 by one or more material bridges (not shown) which remain after molding.

The flexible hinge 34 is then overmoulded, still in the manufacturing mold, to provide a flexible connection between the wall 12 and the flap 32. The aforementioned material bridges are then broken automatically, during demolding to allow the flap 32 of pivoting relative to the flexible wall 12 by means of the hinge 34.

Figure 4 is a view similar to Figure 3 which shows the flap 32 in a complete closed position, in which its lower edge 46 comes into contact with the stop 45. This closed position corresponds to the case where the motor-fan unit is in operation. The air flow (arrow F1) tends to urge the flap 32 to its closed position.

Figure 5 is a view similar to Figure 4 in an open position of the flap when the vehicle is traveling at high speed. The flow of air F2 created by the dynamic pressure, under the effect of the speed of the vehicle, tends to rotate the flap, whose lower edge 46 thus departs from the stop 45.

To facilitate the attachment of the hinge 34 on the respective faces 38 and 40 of the wall 12 and the flap 32, it is possible to provide reliefs or openings allowing the flexible plastic or elastomeric material to penetrate more or less within rigid plastic material. It is thus possible to provide a through opening (not shown) communicating the face 40 of the flap with the opposite face 48 (Figure 3) to allow the plastic material of the hinge to hang at least partly on the face 48 It will also be possible, alternatively or additionally, to provide that the choice of materials involved allows a mutual coupling which is of a chemical nature.

Referring now to FIGS. 6A-6D, there is shown a mold 50 composed of a first portion 52 and a second portion 54 movable mutually between a close position (FIG. 6A) and a remote position (FIG. 6D).

In the close position (FIG. 6A), the two mold parts delimit a mold cavity 56 for the wall and a mold cavity 58 for the shutter. In the illustrated example, these two cavities 56 and 58 communicate with each other to allow material bridges to be created as described previously with reference to FIG.

One or more injectors (not shown) are provided for injecting a first plastic material (rigid plastic material) to jointly mold the wall 12 and the flap 32. During the molding operation, the flap is molded into a substantially closed position as described above with reference to FIG.

Furthermore, the second mold part 54 comprises an injector 60 for injecting a second plastic material (flexible plastic material) and / or elastomer to produce the flexible hinge 34.

The first mold part 52 comprises a housing 62 in which a shutter 64 moves in translation with two shutter fingers 66 and 68. The finger 66 is intended to control the output of the injector 60, while the finger 68 is intended to control an opening 70 which passes through the thickness of the flap. Furthermore, the second mold part 54 has a housing 72 in which a shutter 74 having an end wall 76 intended to control the injection of the flexible plastic material, at the outlet of the injector 60, moves freely. make the hinge flexible.

In the position of Figure 6A, the rigid plastic material has already been injected to jointly mold the wall 12 and the flap 32. The shutter 64 closes the outlet of the injector 60 and the opening 70, while the shutter 74 prevents access of the flexible material to the location corresponding to the flexible hinge.

In the position of Figure 6B, the shutter 64 has moved to the left and the shutter 74 to the right. As a result, the outlet of the injector 60 is no longer closed and the injector 60 can send the flexible plastic material to over mold the flexible hinge on the wall and on the shutter. Note that the flexible material through the opening 70 of the flap, allowing it to cover the other side of the flap to ensure better anchoring of the flexible plastic material.

The second portion 54 of the mold comprises an attachment member 78 in the region corresponding to the lower edge 20 of the flap. In the position of FIG. 6C, the two mold parts 52 and 54 are spaced apart from one another, which allows the mold to pivot slightly under the action of the fastening member 78 and to ensure the rupture of previously existing material bridges between the wall 12 and the flap 32. The two mold parts further apart to the position shown in FIG. 6D where the flap has rotated further relative to the position FIG. 6C under the effect of the attachment member 78. As a result, during the relative displacement of the two mold parts towards the remote position, the joint 12, flap 32 and of the flexible hinge 34. In the example shown in Figures 6A to 6D, only one flap is provided. Of course, it is possible to jointly perform the molding of several flaps and the overmoulding of several flexible hinges.

Generally, at least two flexible hinges will be provided for each flap to provide a better connection as shown in Figures 1 and 2.

Figs. 7A-7D are homologous to Figs. 6B-6D. The main difference is that the attachment member 78, instead of being integral with the mold part 54, is integral with a slide 80 freely movable in a housing 82 of the mold part.

The attachment member 78 is provided at one end of the spool 80, the other end being provided with a double stop 84 limiting the translational movement of the spool 80 in its housing 82. For the rest, the operation of the mold Figs. 7A to 7C are analogous to the operation of the mold of Figs. 6A to 6D. Thus, the molds shown make it possible to carry out the operations a) to d) mentioned above.

It is conceivable, of course, to provide other types of molds to perform the joint molding of the wall of the fan nozzle and the shutter or flaps, and the overmoulding of the flexible hinge or hinges.

It will be understood that the fan nozzle may comprise one or more motor-fan units and one or more air passage openings each controlled by a flap.

In the case where a plurality of air passage openings are provided, these openings and their respective flaps may have different sizes, a different number of hinges, and different hinge geometries, depending on the applications and the possibilities of implantation. on the wall.

In the embodiment previously described as examples, the flaps are free-moving. However, the invention also applies to the case of pivoting flaps whose movement is controlled by a suitable actuator.

The invention thus finds application to automotive vehicles.

Claims (14)

Revendications1. Fan nozzle for motor vehicles, comprising a wall (12) molded and provided with at least one air passage opening (30) for the passage of an air flow, and a flap (32) mounted pivoting device for controlling the flow of air through the air passage opening (30), characterized in that the flap (32) is connected to the wall (12) by at least one flexible hinge ( 34) which is overmolded at least to one face (38) of the wall (12). A fan nozzle according to claim 1 wherein the flap (32) is connected to an edge of the opening (30) by two flexible hinges (34) spaced from one another. Fan nozzle according to one of claims 1 or 2, wherein the flexible hinge (34) is formed in a rubber-like elastomer. 4. Fan nozzle according to one of claims 1 to 3 wherein the flap (32) is integrally molded with the wall and the hinge (34) is overmolded to one side of the flap. 5. Fan nozzle according to one of claims 1 to 4, wherein the wall (12) of the nozzle (10) and the flap (32) are formed in a rigid plastic material. Fan nozzle according to claim 5, wherein the rigid plastics material is a polyamide, in particular glass-filled PA 6 and / or glass filled polypropylene. 14 30 35 7. Fan nozzle according to one of claims 1 to 3 wherein the hinge (34) is made from the material of the flap (32). 8. Fan nozzle according to any one of the preceding claims wherein the fan nozzle is provided with seals, provided at the level of the flaps and / or the wall of the nozzle, to block the passage of the air at the periphery of said openings when the shutter or flaps are in the closed position. 9. A method of manufacturing a fan nozzle (10) according to one of the preceding claims, characterized in that it comprises the following operations: a) provide a mold (50) adapted to mold the wall (12) and the component (s) (32); b) performing a first step of injecting a polymer into the mold to mold the wall (12); C) performing a second step of injecting a polymer into the mold for overmolding at least one flexible hinge (34) on the wall (12); and d) demolding the wall (12) which carries with it the flap (32) and the hinge (34). 25 10. The method of claim 9 wherein the flap is also formed by the first injection step, the flap being housed in the air passage or openings, and the hinge is overmolded to the flap during the second step. injection. The method of claim 10, said method comprising the steps of: a) providing a first mold part (52) and a second mold part (54) movable between a close position and a far position delimiting, in the close position, a demold cavity (56) for the wall (12) and a mold cavity (58) for the flap (32); b) performing said first injection step by simultaneously injecting a polymer into the two molding cavities (54, 56); c) performing said second molding step by then injecting a polymer in a portion of the two cavities, previously closed, to overmold the flexible hinge (34) on the wall (12) and the flap (32); and d) moving the first mold portion (52) and the second mold portion (54) to the remote position to effect joint demoulding of the wall (12), the flap (32) and the flexible hinge (34) . 12. The method of claim 11, wherein, in the first injection step, a polymer is injected into communication passages connecting the two molding cavities (56, 58), which allows material bridges to be created between the wall and the flap, and that in the operation d), the bridges of material are broken by the relative displacement of the first mold part and the second mold part. 13. The method of claim 9 wherein the or flaps (32) are formed by the second injection step, the or flaps (32) being housed in the air passage opening. 14. Method according to one of claims 9 to 13, wherein the flap (32) is molded in a position substantially corresponding to a closed position of the air passage opening (30).