Reconfigurable front and upper one piece baffles for directing incoming air from a vehicle front fascia to a radiator cooling module

Abstract

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.

We claim: 
     
         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.