Air intake device for a vehicle

Abstract

An air inlet device (10) for a vehicle, comprising an air inlet opening (20) with an opening frame (22) for admitting an air flow (LS) along a flow direction (SR) and at least one flow lamella (30) extending transversely in the air inlet opening (20) for influencing the air flow (LS), wherein at least one stabilizing web (40) extends between the opening frame (22) and the at least one flow lamella (30) for mechanically stabilizing the at least one flow lamella (30), wherein the at least one stabilizing web (40) has two web walls (42) aligned along the flow direction (SR) and spaced apart from one another transversely to the flow direction (SR), wherein a web opening (44) is formed between the web walls (42) for the passage of a portion of the air flow (LS), characterized in thatthat the web walls (42) have a thickening at the transition to the opening frame (22) and / or at the transition to the at least one flow lamella (30) for further mechanical stabilization.,

Description

The present invention relates to an air intake device for a vehicle and a method for manufacturing such an air intake device.It is known that vehicles are equipped with air intake devices. These serve to allow an air flow to penetrate into the interior of the vehicle. This is in particular cooling air which is to be supplied to engine components or exhaust system components. Air flows for ventilating the vehicle interior are also supplied to the vehicle. The known solutions have air inlet openings which are provided with grid-like lamellar structures. These flow blades of the ventilation grilles serve on the one hand to prevent any larger solid particles from entering through the air inlet opening. Secondly, influencing the flow of the air flow through such a flow lamella is possible. The publications DE 10 2015 209 563 B3, DE 10 2009 056 841 A1, DE 200 21 023 U1, DE 103 41 983 A1, DE 103 37 751 B3 and DE 43 13 979 A1 show air inlet devices.It is disadvantageous in the known solutions that they have to be produced relatively expensively. A further disadvantage is the reduction of the flow volume through the air inlet opening due to stabilizing webs which extend between the individual flow fins. Such stabilizing webs have a relatively wide cross section for mechanical stabilization, so that they provide a large degree of masking for air flow. In order to achieve a sufficiently large volume flow of air flow through the air inlet opening, a sufficiently high mechanical stabilization must be ensured on the one hand and a particularly large opening area must be provided for the air inlet opening on the other hand. This has the result that the design freedom in the design of the vehicle is reduced, in particular in the front section. The overall air resistance of the vehicle is also impaired by the enlarged cross-sectional areas of the individual stabilizing webs.It is an object of the present invention to at least partially eliminate the disadvantages described above. In particular, it is an object of the present invention to provide an improved air inlet device and an improved method for producing an air inlet device.The above object is achieved by an air inlet device having the features of claim 1 and a method having the features of claim 9. Features and details which are described in connection with the air inlet device according to the invention naturally also apply in connection with the method according to the invention and vice versa, so that with regard to the disclosure reference is or can always be made reciprocally to the individual aspects of the invention.According to the invention, an air intake device for a vehicle is provided. This has an air inlet opening with an opening frame for the inlet of an air flow along a flow direction, and at least one flow slat is provided, which extends transversely in the air inlet opening. In this case, at least one stabilizing web extends between the opening frame on the one hand and the at least one flow lamella on the other hand for a mechanical stabilization of the at least one flow lamella. According to the invention, the air inlet device is further equipped with at least one stabilizing web in such a way that it has two web walls which are aligned along the flow direction and are spaced apart from one another transversely to the flow direction. In this case, a web opening is formed between the web walls for a passage of a part of the air flow.In contrast to the known solutions of air inlet devices, the air inlet devices according to the invention are now equipped with improved stabilizing webs. In contrast to the known relatively thick stabilizing webs, the stabilizing webs according to the invention are now formed in multiple parts. This multi-part structure is supported in particular by two separate web walls. These two web walls are each likewise aligned along the flow direction, so that they offer only a low individual resistance to the air flow along the flow direction. Whereas in the known solutions of individual and integrally formed stabilizing webs these had to have a certain minimum width for the necessary mechanical stabilization, this minimum width can likewise be achieved in the case of separate web walls in the case of a stabilizing web according to the invention. The entire width of the stabilizing web will not, however, act as a covering surface for the air flow, since a web opening is now located between these two web walls in a manner according to the invention. In other words, the stabilizing web is now provided on the one hand with a sufficient width for the necessary mechanical stabilization. On the other hand, however, this width is broken open again by the web opening, so that despite the stabilizing width, the stabilizing web has a low degree of masking, since with the aid of the web opening, at least a portion of the air flow can, as it were, flow through the stabilizing web along the two web walls and between these two.In a manner according to the invention, the mechanical stability of known stabilizing webs can thus be achieved, since the width of the respective stabilizing web can be retained or even widened. The previously disadvantageous effect of the high degree of masking with a high mechanical width of the individual stabilizing webs is, however, eliminated by the provision of the individual web openings. Thus, the compromise necessary hitherto between the widest possible webs for the stabilizing effect and the narrowest possible webs for a low degree of masking can be eliminated, so that now, independently of the mechanical stabilization, an air flow which is as advantageous as possible can be constructed and provided.Of course, in an air inlet device according to the invention, a plurality of two, three or more flow vanes can also be provided. The individual stabilizing webs can extend between the individual flow vanes and also from the respective opening frame to the adjacent flow vane. The individual stabilizing webs also preferably pass through the flow fins, so that a uniform pattern and a uniform extension are obtained from one side of the opening frame, preferably from the lower part of the opening frame, to the other side of the opening frame, preferably the upper part. Of course, among other geometric alignments, a rectangular or substantially rectangular grid can preferably form, so that in the opening frame the individual flow vanes extend parallel transversely and the individual stabilizing webs extend longitudinally or vertically in the air inlet opening. However, other angles or angular alignments of the individual components with respect to one another are also possible in a manner according to the invention.In addition to the fact that the air flow can now be optimized with constant or even improved mechanical stabilization effect, the possibility of producing an air inlet device according to the invention is also improved. While in the known solutions wide stabilizing webs may necessitate a higher outlay in production, for example due to the corresponding provision of wide draft angles or corresponding transition sections between different material diameters or material thicknesses, a cost-effective manner of construction is also possible in accordance with the invention for a cost-effective production method.It can be advantageous if, in an air inlet device according to the invention, the two web walls have an acute opening angle with respect to one another, which opens in the flow direction. In other words, the passage cross section thus widens from the web opening to the rear in the flow direction. This has two decisive advantages in particular. On the one hand, an improvement in the flow can be achieved in this way, since dynamic pressure or baffle sections for air flow which flows through the web opening are avoided. By opening the opening angle, the nozzle effect within the web opening is reduced, so that undesired vortex formation can be avoided and an improved flow with a higher volume flow can be achieved. In addition to improving the flow, the opening acute opening angle between the two web walls also makes possible an easier fabrication. In the case of a possibility for manufacturing from plastic, for example with the aid of an injection molding method, easier mould release from an associated cavity of a tool device or an injection mold is possible due to the pointed opening angle opening towards the rear. The individual side surfaces of the web walls can be designed as draft angles.In addition, it can be advantageous if, in the case of an air inlet device according to the invention, the two web walls are designed and / or arranged in mirror-image or substantially mirror-image fashion with respect to one another. The mirror-image configuration is given in particular in an identical manner, so that the design outlay is significantly reduced. A mirror-image configuration furthermore leads to a flow through the web opening being able to take place substantially free of a lateral transverse deflection of the flow direction. In addition to the simplified design possibility, easier mouldability will also be provided. In particular, this embodiment is combined with an acute opening angle, as explained in the preceding paragraph.It is further advantageous if, in an air inlet device according to the invention, at least one of the two web walls has, in the region of the web opening, a wall projection which projects into the web opening. Such a wall projection can be designed in the manner of a nose or have a corresponding thickening. Preferably, the mirror-image configuration explained in the preceding paragraph is provided here, so that this wall projection is provided on both sides, and accordingly on both web walls. For the production possibility, this likewise leads to improved mouldability. With regard to the flow, a further improvement takes place since here too an increased opening effect takes place in the flow direction during the flow with air flow. Not least, the provision of such wall projections additionally leads to a further mechanical stabilization of the web walls and thus to the stabilizing effect of the stabilizing web.It can likewise be advantageous if, in the case of an air inlet device according to the invention, the web walls extend transversely or substantially transversely with respect to the at least one flow lamella. A grid structure can thus be provided which in particular provides vertical or vertical sections through the web walls and horizontal or horizontal sections through the flow lamellae. In addition to an improved production possibility, a simple and cost-effective solution is provided in this way, which provides substantially ideal or at least optimized flow conditions for the flow of the air flow.In addition, it is advantageous if, in an air inlet device according to the invention, the at least one flow lamella, the opening frame and / or the at least one stabilizing web are formed integrally, in particular monolithically. The individual components are preferably also made of a uniform material in the same material or in one piece. This is in particular a plastic or a plastic mixture. The possibility of producing it in a simple and cost-effective injection molding process is preferred in this way. The mould release, which will be explained later, is preferably formed along the flow direction.In an air inlet device according to the invention, the web walls have a thickening at the transition to the opening frame and / or at the transition to the at least one flow lamella for a further mechanical stabilization. Such thickening leads to a local increase in the material thickness and will in particular reduce undesired notch stresses or notch effects at these transitions. In particular when manufacturing from a plastic material, such a thickening can be formed directly during the manufacturing method by a corresponding formation in the negative form of the cavity of an injection molding tool.It is furthermore advantageous if, in an air inlet device according to the invention, at least two flow vanes are arranged parallel or substantially parallel to one another in the air inlet opening. The provision of two or more flow lamellae reduces the free passage cross section, so that the grid functionality and thus the protection against the penetration of solid bodies is further improved. The finer the grid, the better the air flow can be influenced in parallel and thus in uniformity of flow. The individual stabilizing webs preferably extend through the flow lamellae and thus also between the parallel flow lamellae with respect to one another.In addition, it can be advantageous if, in the case of an air inlet device according to the invention, the web walls and / or the flow vanes have draft angles for easier demolding from an injection mold. An injection mold makes it possible to produce the air inlet device cost-effectively and easily, in particular from a plastic material. The draft angles, which can also be designed as draft surfaces, are in particular part of the individual web walls, but also part of the individual flow fins.Another object of the present invention is a method for manufacturing an air intake device according to the present invention. Such a method comprises the following steps:providing an injection molding tool having a cavity in the negative form of the air inlet device,introducing liquid injection molding material into the cavity,curing the injection molding material in the cavity to the air inlet device,demolding the air inlet device along the flow direction.By forming an air inlet device according to the invention, a method according to the invention brings with it the same advantages as have been explained in detail with reference to an air inlet device according to the invention. In particular, the correlation of the demolding direction with the flow direction is possible by the configuration according to the invention and narrow construction of the individual stabilizing webs.Further advantages, features and details of the invention will become apparent from the following description, in which exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination. They show schematically: FIG. 1 shows a first embodiment of an air inlet device according to the invention, FIG. 2 shows an embodiment of a stabilizing web, FIG. 3 shows a further embodiment of a stabilizing web, FIG. 4 shows a further embodiment of a stabilizing web, FIG. 5 shows a further embodiment of a stabilizing web, FIG. 6 shows a further embodiment of a stabilizing web, FIG. 7 shows a first step of a method according to the invention, FIG. 8 shows a further step of a method according to the invention, and FIG. 9 shows an air inlet device produced by a method according to FIGS. 7 and 8.In FIG. 1, it is schematically shown how an air inlet device 10 can be arranged on a vehicle. This is a front view in the area of the front lip or the front spoiler of the vehicle. Here, the air intake device 10 is arranged to introduce an air flow LS from the surroundings of the vehicle into the interior of the vehicle. In this region, the air flow LS can be drawn in or introduced in order to provide an air flow for cooling the engine, for supplying air to the combustion part of the engine or for supplying air flow LS for ventilating the passenger compartment of the vehicle. The air inlet device is provided here in the form of a grid with a plurality of flow fins 30 and corresponding stabilizing webs 40. The flow vanes 30 extend transversely and the stabilizing webs 40 extend vertically within the opening frame 20 in the air inlet opening 20 of the air inlet device 10.FIGS. 2 to 6 now show several embodiments of an air inlet device 10 with regard to the different possibilities for stabilizing webs 40. By means of this spacing of the web walls 42 transversely to the flow direction SR of the air flow LS, a corresponding stabilization width is provided, which provides a mechanical stabilization effect on the flow vanes 30 arranged at the top and at the bottom or on the adjacent opening frame 22. In order to now reduce the masking effect in the flow direction SR for the respective stabilizing web 40, all stabilizing webs 40 of FIGS. 2 to 6 are equipped with a central web opening 44. This web opening 44 is formed in that the two web walls 42 are now spaced apart from one another transversely to the flow direction SR of the air flow LS and in this way the web opening 44 is formed for a flow with the air flow LS along the flow direction SR. FIGS. 2 to 5 show how the distance between the individual web walls 42 can increase and thus a widening and in this way a mechanical improvement of the stabilizing effect of the stabilizing webs 40 can be achieved. Despite the increasing widening of the stabilizing webs 40 from FIG. 2 to FIG. 5, the degree of masking is in no way impaired, since for all these embodiments a corresponding configuration with a central web opening 44 enables the flow of the entire stabilizing web 40 with the air flow LS along the flow direction SR. It can also be seen from FIGS. 2 to 5 that a mirror-image configuration is provided here, which in particular provides improved mouldability. If, as will be explained later on with reference to FIGS. 7 to 9, an injection molding method is used for the production of the air inlet device 10, then demolding from an associated cavity 110 can now take place easily, cost-effectively and quickly along the flow direction SR.FIGS. 2 to 6 also show a wall projection 46, which is arranged at the end of the two web walls 42 directed opposite to the flow direction SR. FIG. 6 is shown with a non-mirror-image configuration of the individual web walls 42, wherein here too the central web opening 44 enables the reduced degree of masking despite the large, wider stabilizing web 40. In a preferred embodiment, the conversion projection has a minimum radius according to the ECE-R26 regulation.FIGS. 7 to 9 show a possibility for producing an air inlet device 10. Liquid injection molding material is now introduced into this cavity 110 and cured there to form the air inlet device 10 according to FIG. 8. As soon as the curing process is finished, the demolding step can take place in the direction of the flow direction SR, so that in this way a cost-effective, simple and fast production possibility for an air inlet device 10 according to FIG. 9 is provided.The foregoing explanation of the embodiments describes the present invention solely by way of examples. Of course, individual features of the embodiments can be freely combined with one another, insofar as technically expedient, without departing from the scope of the present invention.

Claims

Air inlet device (10) for a vehicle, having an air inlet opening (20) with an opening frame (22) for the inlet of an air flow (LS) along a flow direction (SR) and at least one flow lamella (30), which extends transversely in the air inlet opening (20), for influencing the air flow (LS), wherein at least one stabilizing web (40) extends between the opening frame (22) and the at least one flow lamella (30) for a mechanical stabilization of the at least one flow lamella (30), wherein the at least one stabilizing web (40) has two web walls (42), which are aligned along the flow direction (SR) and are spaced apart from one another transversely to the flow direction (SR), wherein a web opening (44) is formed between the web walls (42) for a passage of a part of the air flow (LS)da., characterized in thatthe air inlet device has, the web walls (42) have a thickening at the transition to the opening frame (22) and / or at the transition to the at least one flow lamella (30) for further mechanical stabilization.Air inlet device (10) according to Claim 1, characterized in that the two web walls (42) have an acute opening angle (α) with respect to one another, which opens in the flow direction (SR).Air inlet device (10) according to one of the preceding claims, characterized in that the two web walls (42) are designed and / or arranged mirror-symmetrically or substantially mirror-symmetrically with respect to one another.Air inlet device (10) according to one of the preceding claims, characterized in that at least one of the two web walls (42) has, in the region of the web opening (44), a wall projection (46) which projects into the web opening (44).Air inlet device (10) according to one of the preceding claims, characterized in that the web walls (42) extend transversely or substantially transversely with respect to the at least one flow lamella (30).Air inlet device (10) according to one of the preceding claims, characterized in that the at least one flow lamella (30), the opening frame (22) and / or the at least one stabilizing web (40) are formed integrally, in particular monolithically.Air inlet device (10) according to one of the preceding claims, characterized in that at least two flow fins (30) are arranged parallel or substantially parallel to one another in the air inlet opening (20).Air inlet device (10) according to one of the preceding claims, characterized in that the web walls (42) and / or the flow fins (30) have draft angles for easier demolding from an injection mold.Method for producing an air inlet device (10) having the features of one of Claims 1 to 8, having the following steps: - providing an injection-molding tool (100) having a cavity (110) in the negative form of the air inlet device (10), - introducing liquid injection-molding material into the cavity (110), - curing the injection-molding material in the cavity (110) to form the air inlet device (10), - demolding the air inlet device (10) along the flow direction (SR).

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