Active grille shutter in-tool assembly

Patent metadata

Field	Value
Publication number	US-2023106937-A1
Application number	US-202117914416-A
Country	US
Kind code	A1
Filing date	May 4, 2021
Priority date	May 4, 2020
Publication date	Apr 6, 2023
Grant date	—

Abstract

A method of in tool formation and assembly of an active grille shutter system, followed by an automated testing process. The method includes providing a tool having a plurality of sliders that assist in the formation and assembly of the active grille shutter system. The components of the active grille shutter system are individually formed in a single tool, with each of the components being spaced apart from each other. After formation of the components a number of sliders and an end of arm tool push the components together to form the assembled active grille shutter system. The end of arm tool then takes the assembled active grille shutter system to a testing station where the operation is checked.

First claim

What is claimed is:

1 . A method of forming an active grille shutter system comprising the steps of:
providing a tool having at least two core pieces moveable between a closed and open position wherein when the at least two core pieces are in the forming position a forming cavity is formed that defines molding surfaces for forming a plurality of components of an active grille shutter system, wherein the at least two core pieces include a base core piece that form part of the forming cavity; providing one or more pushers each having a forming surface that forms part of the forming cavity and are moveable between a forming position and an assembly position; closing the tool and moving the at least two core piece and the one or more pushers to the forming position; forming the plurality of components of an active grille shutter system in the forming cavity; and moving the one or more pushers against the plurality of components and pushing the plurality of components together to form an active grille shutter system.

2 . The method of forming the active grille shutter system of claim 1 further comprising the steps of:
providing a plurality of sliders that are moveable between a forming position and an extended position, and
wherein during the forming of the plurality of components the plurality of sliders are in the forming position the plurality of sliders are positioned inside of the forming cavity to fill spaces between the plurality of components.

3 . The method of forming the active grille shutter system of claim 1 further comprising the steps of:
providing an actuator;
providing an end of arm tool having an actuator holding member, and
connecting an actuator to the actuator holding member of the end of arm tool;
inserting the actuator into one of the plurality of components using the end of arm tool and releasing the actuator from the actuator holding member.

4 . The method of forming the active grille shutter system of claim 3 further comprising the steps of:
providing a testing station with an electrical connector, and
holding the active grille shutter system with a plurality of gripping members on the end of arm tool;
moving the active grille shutter system off of the base core piece with the end of arm tool;
moving the active grille shutter system to the testing station, and
connecting the actuator to an electrical connector at the testing station and performing a test of the active grille shutter system.

5 . The method of claim 4 further comprising the steps of:
providing a plurality of sliders that are moveable between a forming position and an extended position;
wherein during the forming of the plurality of components the plurality of sliders positioned in the forming position the plurality of sliders are positioned inside of the forming cavity to fill spaces between the plurality of components;
grasping the active grill shutter system with the plurality of gripping members of the end of arm tool, and
wherein the step of moving the active grille shutter system off of the base core piece with the end of arm tool further includes moving the plurality of sliders to the extended position to assist with moving the active grille shutter system off the base core piece by pushing on the active grille shutter system.

6 . The method of forming an active grille shutter system of claim 1 further comprising the steps of:
providing one or more preformed components;
inserting the one or more preformed components into the tool prior to the step of closing the tool.

7 . The method of forming an active grille shutter system of claim 6 wherein the one or more preformed components include one or more selected from the group consisting of a top side of the frame, a bottom side of the frame or one or more vanes.

8 . The method of claim 7 wherein the one or more preformed components are formed during a separate extrusion step outside of the tool.

9 . A method of forming an active grille shutter system comprising the steps of:
providing a tool having at least two core pieces moveable between a closed and open position wherein when the at least two core pieces are in the forming position a forming cavity is formed that defines molding surfaces for forming plurality of components of an active grille shutter system, wherein the at least two core pieces include a base core piece that form part of the forming cavity; providing one or more pushers each having a forming surface that forms part of the forming cavity and are moveable between a forming position and an assembly position; providing an end of arm tool having a plurality of gripping members and an actuator holding member for holding an actuator; providing a testing station having an electrical connector capable of supplying power to the actuator; closing the tool and moving the at least two core pieces and the one or more pushers to the forming position; forming a plurality of components of an active grille shutter system in the forming cavity; opening the mold tool and moving the end of arm tool with the actuator attached to the actuator holding member into position over the plurality of components and placing the plurality of gripping members into contact with at least one of the plurality of components, wherein the end of arm tool also connects the actuator to one of the plurality of components when the end of arm tool contacts the plurality of components; moving the one or more pushers against the plurality components and pushing the plurality of components together to form an active grille shutter system; holding the active grille shutter system with the plurality of gripping members; moving the end of arm tool with the active grille shutter system attached off of the base core piece, and using the end of arm tool to transfer the active grill shutter system to the testing station and connecting the actuator of the active grille shutter system to the electrical connector and performing a test of an operation of the active grille shutter system.

10 . The method of forming an active grille shutter system of claim 9 further comprising the steps of:
providing one or more preformed components;
inserting the one or more preformed components into the tool prior to the step of closing the tool.

11 . The method of forming an active grille shutter system of claim 10 wherein the one or more preformed components include one or more selected from the group consisting of a top side of the frame, a bottom side of the frame or one or more vanes.

12 . The method of claim 11 wherein the one or more preformed components are formed during a separate extrusion step outside of the tool.

13 . The method of claim 9 further comprising the steps of:
providing a plurality of sliders connected to the base core piece that are moveable between a forming position and an extended position;
wherein during the forming of the plurality of components the plurality of sliders are positioned in the forming position so that the plurality of sliders are positioned inside of the forming cavity to fill spaces between the plurality of components;
grasping the active grill shutter system with the plurality of gripping members of the end of arm tool, and
wherein the step of moving the end of arm tool with the active grille shutter system attached off of the base core piece further includes moving the plurality of sliders to the extended position to assist with moving the active grille shutter system off the base core piece by pushing on the active grille shutter system.

14 . A method of forming an active grille shutter system comprising the steps

Assignees

• Lindberg Braendon R
• Magna Exteriors Inc

Inventors

• Lindberg Braendon R
• Rusev Rosen
• Zorn Michael

Classifications

• B29C45/14 Primary

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• Y02T10/88

  Optimized components or subsystems, e.g. lighting, actively controlled glasses · CPC title

• B29C2945/76903

  After-treatment · CPC title

• B60K11/085

  with adjustable shutters or blinds · CPC title

• B29C45/26

  Moulds · CPC title