Air flow control device for automotive front module

Abstract

An airflow control device for a front module of a motor vehicle, the control device comprising a frame and a plurality of vanes extending within and rotatably mounted to the frame, each vane rotatable about an axis of rotation substantially parallel to a primary direction of extension of each vane, the vanes rotatable between an open position and a closed position, the frame including an integral support bar extending in a direction perpendicular to the primary direction of extension of the vanes, the vanes having fins configured to rest on the support bar when the vanes are closed and subject to pressure towards the support bar.

Description

[Technical field]

[0001] The field of the invention is that of the heat treatment of different zones or parts of a motor vehicle. More specifically, the invention relates to the cooling units used for this purpose and more particularly to the devices used to regulate the air flow in such units. [Background technology]

[0002] The use of movable vanes, e.g. vanes arranged on the front of a vehicle to reduce the drag coefficient of the vehicle, is known. Such movable vanes can be adjusted, for example by an actuator connected to a drive motor, to improve the cooling and / or air conditioning performance within the vehicle. More generally, such movable vanes can be used to control the passage of an air flow intended to pass through one or more elements arranged in the engine compartment of the vehicle.

[0003] Such a device is preferably positioned in the front grille of the relevant motor vehicle and is known as AGS, an acronym for "Active Grill Shutter". In the open position of the movable vanes of such a device, air can flow through the grille and can be particularly useful for cooling the engine of the vehicle, for example by passing through one or more heat exchangers of a cooling unit of the vehicle. In the closed position of the movable vanes of such a device, the flow of air through the grille is prevented, thereby reducing the drag of the vehicle and thus reducing fuel consumption, in particular carbon dioxide emissions.

[0004] The AGS device therefore allows to reduce the vehicle's energy consumption and the pollution caused thereby, as the vehicle's engine does not need to be cooled by outside air. In a known manner, the movable vanes of such a device integrally form a substantially flat surface in the closed position.

[0005] The vanes are subjected to pressure resulting from the movement of the vehicle, either due to air or water (in so-called fording). As the vanes are long and are usually only supported at the sides, the pressure causes large deformations in the centre of the vane. In some cases, the deformations cause unwanted contact with elements such as cooling modules located further downstream. This can occur particularly in the closed position of the vanes. In the open configuration of the AGS, on the other hand, the same long vanes can deform vertically due to vibrations, generating unwanted noise.

[0006] It would be desirable to provide an air flow control device that would alleviate the above-mentioned problems, and in particular, it would be desirable to do so in a cost-effective and simple manner. Summary of the Invention

[0007] The object of the present invention is, inter alia, an airflow control device for a front module of a motor vehicle, said device comprising a frame and a plurality of vanes extending therein and rotatably mounted thereto, each vane being rotatable about an axis of rotation substantially parallel to the main direction of extension of each vane, said vanes being rotatable between an open position and a closed position, said frame including an integral support bar extending in a direction Vi perpendicular to the main direction of extension of the vanes, the vanes having fins arranged to rest on the support bar when the vanes are closed and are subjected to pressure towards the support bar.

[0008] In one embodiment, the fins project from the vanes a distance that substantially corresponds to the distance between the vanes in the open position.

[0009] In one embodiment, the frame includes a support protrusion at one end of the integral support bar, the support protrusion protruding toward the nearest vane so as to substantially abut the vane in its closed position.

[0010] In one embodiment, the frame includes a support groove at one end of the integral support bar, the support groove configured to receive a fin of a nearest vane.

[0011] In one embodiment, the integral support bar has guide grooves extending along its length to receive fins at any position.

[0012] In one embodiment, the support bar includes a quarter-circular notch within which the vane is received and supported in the closed position, the notch having a shape to guide movement of the vane toward the open position.

[0013] In one embodiment, the support bar is perforated.

[0014] In one embodiment, the fin has a substantially triangular shape.

[0015] In one embodiment, the fins have a substantially semi-circular shape.

[0016] In one embodiment, the edges of the fins are made of a vibration dampening material.

[0017] In one embodiment, the apparatus includes a plurality of support bars, the vane comprising a plurality of respective fins adapted to operate with the plurality of support bars.

[0018] According to the invention, each vane has the overall shape of a blade or a thin panel extending in the main direction of extension of the vane considered (hereinafter also called longitudinal direction), with respect to which the transverse direction of the vane is defined as the direction which, together with the longitudinal direction defined above, defines the active surface of the vane, i.e. the surface of the vane which is intended to be placed in the air flow with the purpose of modifying or not modifying the flow before it reaches the cooling unit of the vehicle. The vertical direction of the vane is also defined as the direction perpendicular to both the longitudinal and transverse directions of the vane defined above. The vertical direction therefore defines the thickness of the vane.

[0019] For each vane of the assembly according to the invention, the longitudinal, transverse and vertical directions defined above together form a regular trihedron. For flow reasons and for reasons related to installation and / or manufacturing constraints, each vane may have a substantially convex shape in its transverse direction. In this example, the vertical direction of a vane will be defined as the one in which the thickness of the blade forming the vane considered extends at the apex of the curvature of the convex shape. It is noted in all cases that the above mentioned vertical direction may have any orientation with respect to the vertical direction of the vehicle for each vane of the set of vanes according to the invention.

[0020] According to the invention, each vane is rotatable about an axis of rotation substantially parallel to the longitudinal direction, i.e. the main direction of extension, of the vane. More specifically, each vane of a set of vanes according to the invention is movable between a first closed end position and a second open end position, between which positions each vane can assume all intermediate angular positions about its axis of rotation. Thus, on the one hand, it is possible to define a closed position of the set of vanes according to the invention, in which all the vanes forming the set are simultaneously in their closed position, and on the other hand, it is possible to define an open position of the set of vanes according to the invention, in which all the vanes forming the set are simultaneously in their open position.

[0021] It must be understood here that in a set of vanes according to the invention, advantageously all vanes at each instant are in the same relative angular position with respect to the axis of rotation defined above, in other words in a set of vanes according to the invention, all vanes rotate simultaneously through the same angle about their respective axes of rotation.

[0022] In the closed position of the set of vanes according to the invention, the vanes of said set together form a substantially continuous surface. More specifically, this substantially continuous surface is configured to prevent airflow from passing through the set of vanes according to the invention. According to a non-limiting embodiment, the closed position of the set of vanes according to the invention may correspond to a substantially zero angular rotation of each of the vanes about the axis of rotation. The angular position corresponding to the closed position of each of the vanes is then defined as an initial angular position for measuring the rotation angles of these vanes.

[0023] In the open position of a set of vanes according to the invention, the vanes of said set allow the air flow to pass through the set of vanes according to the invention without significant flow modification. By way of non-limiting example, the open position of a set of vanes according to the invention may correspond to an angular rotation of the order of 90 degrees of each of the vanes about their axis of rotation. The angle of rotation is measured from an arbitrarily defined initial angular position.

[0024] Between the open and closed positions, a set of vanes according to the present invention may assume all intermediate angular positions such that when the set of vanes is positioned such that an air flow is intended to pass through the set of vanes, the set of vanes according to the present invention will accommodate such air flow to be greater or smaller.

[0025] Advantageously, the vanes of a set of vanes according to the invention are assembled with the closest manufacturing and assembly tolerances such that their respective axes of rotation are substantially parallel to one another. In other words, the vanes of a set according to the invention are assembled such that their longitudinal directions are all parallel to one another without coincidence. The longitudinal direction of a set of vanes according to the invention is defined as any one of the longitudinal directions of the vanes of the set which are all parallel to one another.

[0026] In the set of vanes according to the invention, the vanes are arranged substantially side by side, preferably in an overlapping configuration along their longitudinal edges, in the closed position defined above of the set of vanes. According to one feature of the invention, the vanes may have flexible lips at their longitudinal edges. In this way, the vanes may be arranged in the above-mentioned closed position. Advantageously, the vanes may be arranged such that there remains between two adjacent vanes a space sufficient for each of these vanes to rotate and which prevents the passage of air flow in the closed position of each of these vanes.

[0027] In order that all vanes rotate simultaneously, the set of vanes according to the invention is provided with a common link, which according to the invention is a complex substantially planar part arranged with the closest manufacturing and assembly tolerances substantially perpendicular to the longitudinal axis of the air flow control device as defined above, i.e. substantially perpendicular to the direction of the rotation axes of each of the vanes, which are all parallel to each other as indicated above.

[0028] According to the invention, each vane is connected at one of its longitudinal ends to a common link via at least one guide pad, so that its movement causes a corresponding movement of all the vanes of the set according to the invention.

[0029] More specifically, each of the vanes is connected at one of its longitudinal ends, on the one hand, to a structural element, for example the chassis or frame of the front module or the housing of the cooling unit, and / or to a support frame with bearings, also called journals, in which the vanes, and in particular their axis of rotation, are introduced, and on the other hand, to a common link. A movement of the plate causes a movement of the connection point of each vane on the plate, thereby causing each of the vanes to pivot about a fixed point of rotation formed by the joining zone between the vane and the structural element.

[0030] The invention will be explained in more detail below with reference to the drawings. [Brief description of the drawings]

[0031] [Figure 1] FIG. 1 is a schematic perspective front view of an air flow control device according to the present invention in a closed position. [Diagram 2] FIG. 2 is a schematic perspective rear view of an air flow control device according to the present invention in a closed position. [Diagram 3] FIG. 3 is a schematic perspective front view of an air flow control device according to the present invention in an open position. [Figure 4] FIG. 4 is a schematic perspective rear view of an air flow control device according to the present invention in an open position. [Diagram 5] FIG. 5 shows a schematic diagram in top view of an embodiment of an air flow control device according to the invention. [Figure 6] 6 is a perspective cross-sectional view of the airflow control device of FIG. [Figure 7] 7 is a partial cross-sectional view of the airflow control device of FIG. [Figure 8a] FIG. 8a shows a close-up view of the top of the support bar. [Figure 8b] FIG. 8b shows a close-up view of the top of the support bar. [Figure 9a] FIG. 9a shows a close-up view of the lower part of the support bar. [Figure 9b] FIG. 9b shows a close-up of the lower part of the support bar. [Figure 10]FIG. 10 shows an embodiment of a vane having multiple fins. [Figure 11] FIG. 11 illustrates an embodiment of the airflow control device having the vanes of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] With reference to FIG. 1, an airflow control device 500 according to the invention may comprise a support frame 10. The support frame 10 comprises N bearings of the front module, or the actual chassis of the front module, into which N vanes 1a, 1b... are inserted. Each vane is rotatable about an axis of rotation 100a, 100b, respectively. In the following, the generic designation 1i is used for any of the vanes 1a, 1b,... 1N. It is understood that all of the vanes 1a, 1b,... 1N have the same characteristics for the invention. The detailed description given below for the vane 1i is therefore valid for all the vanes 1a,... 1N of the airflow control device 500 according to the invention. This designation also applies to other components as appropriate.

[0033] The airflow control device 500 according to the invention is intended to be placed in the airflow indicated by the arrow A in FIG. 1. The purpose is to regulate the flow depending on the position of the vanes 1a, ... 1N relative to the flow direction of the airflow A. The airflow control device 500 according to the invention may be intended to be placed between the air intake of the vehicle, not shown in the drawings, and a cooling unit of the vehicle, not shown in the drawings, or at the outlet of the cooling unit, between said unit and the cooled element of the vehicle, or even at or immediately after the front grill of the vehicle. According to various embodiments, the cooling unit may be, in a non-limiting manner, a heat exchanger of a refrigerant circuit or another element of a heat transfer fluid circuit intended to cool one or more parts of the vehicle under consideration. It is to be understood here that A refers to the airflow as well as the water flow when the vehicle crosses a water field (so-called fording).

[0034] With reference to FIG. 1, the vane 1i of the airflow control device 500 according to the invention has the overall shape of a blade or thin panel extending in a main extension direction Li, which will hereinafter also be referred to as the longitudinal direction Li of the vane 1i. With respect to the longitudinal direction Li, the transverse direction Ti of the vane 1i is defined as a direction which, together with the aforementioned longitudinal direction Li, defines an active surface Si of the vane 1i. Here, the active surface Si is defined as the surface of the vane 1i intended to be placed in the aforementioned airflow A in order to regulate the flow depending on the relative orientation of the surface Si with respect to the direction of the airflow A. According to a non-limiting embodiment shown in more detail in the drawings, the vane 1i has a substantially convex shape in its transverse direction Ti, the apex of its curvature pointing towards the opposite side of the aforementioned airflow A. In addition to the longitudinal direction Li and the transverse direction Ti of the vane 1i, the vertical direction Vi of the vane 1i is defined as perpendicular to both the aforementioned longitudinal direction Li and the transverse direction Ti. In the illustrated embodiment, the vane 1i has a honeycomb structure, which provides high structural strength.

[0035] According to an embodiment shown in more detail in Figure 1, the vertical direction Vi may be defined as the direction in which the thickness of the vane 1i extends at the apex of the convex curvature of the vane in its transverse direction Ti. For each vane 1i, the longitudinal direction Li, the transverse direction Ti and the vertical direction Vi form a regular triangle (Li, Ti, Vi) as shown in Figure 1.

[0036] As is clear from Fig. 1, in the airflow control device 500 according to the present invention, the vanes 1i are assembled with the closest manufacturing and assembly tolerances so that their longitudinal directions Li are all substantially parallel to each other. More specifically, as is clear from Fig. 1, the vanes 1i are stacked such that the longitudinal directions Li substantially parallel to each other do not coincide with each other to form the airflow control device 500 according to the present invention. Hereinafter, the longitudinal direction of the airflow control device 500 according to the present invention refers to any one of the longitudinal directions Li described above.

[0037] According to the present invention, each vane 1i is rotatable about a rotation axis 100i that is substantially parallel to the longitudinal direction Li of the vane 1i. As a result, the rotation axes 100i of the vanes 1i of the airflow control device 500 according to the present invention are all distinct from one another and substantially parallel to one another within the closest manufacturing and assembly tolerances.

[0038] Each vane 1i of the airflow control device 500 according to the present invention is movable between a first closed end position and a second open end position, and between these positions, each vane can take all intermediate angular positions with respect to its rotation axis 100i. It should be noted that according to the present invention, all vanes 1i are always in the same relative angular position with respect to their respective rotation axes 100i. In other words, in the airflow control device 500 according to the present invention, all vanes 1i rotate simultaneously at the same angle around their respective rotation axes 100i.

[0039] Figure 1 shows more specifically the airflow control device 500 according to the invention in a closed position for all vanes 1i forming the set. This position is also referred to as the closed position or closed configuration of the airflow control device 500. In this position, as is evident from Figure 1, the active surfaces of the vanes li as defined above integrally form a substantially continuous surface S. As shown in Figure 1, the substantially continuous surface S is configured such that the airflow A as defined above does not pass through the airflow control device 500 and has a curvature adapted to the integration of a set of vanes in a motor vehicle.

[0040] In other words, each vane 1i is rotatable about an axis of rotation 100i and is configured to transition from an open or open configuration of the frame 10, or a configuration or position referred to as an open or open position, in which each vane 1i opposes as little as possible to the flow of air through the openings defined by the frame 10, to a closed or sealed configuration of the frame 10, or a configuration or position referred to as a closed or sealed position, in which each vane 1i opposes as much as possible to the flow of air flow while the set of vanes 1i does not allow air flow through the openings in the frame.

[0041] In other words, the vanes 1i are arranged such that in their closed position within the airflow control device 500, the vanes are disposed substantially side-by-side along their longitudinal edges. The angular position of each vane 1i about its axis of rotation 100i in the closed position of the vane under consideration is arbitrarily designated as 0 degrees.

[0042] In the open position of the vanes 1i, also denoted as the open position of the airflow control device 500 according to the invention shown in Figures 3 and 4, the vanes 1i allow the airflow to pass through the airflow control device 500 without significantly modifying the flow of this airflow. With reference to the previously defined angular positions corresponding to the closed positions of each vane 1i, the angular position of each vane 1i about its axis of rotation 100i in the open position of the vane 1i considered may be, according to a non-limiting embodiment, of the order of 90 degrees.

[0043] Between the open position of the airflow control device 500 according to the invention and its closed position, the vanes 1i forming this set can take all angular positions with respect to their respective axes of rotation, with the purpose of regulating the airflow A passing through the airflow control device 500 by modifying the amount of air passing through said device.

[0044] According to an embodiment, each vane 1i is substantially flat in its lateral direction Ti.

[0045] 2, the airflow control device 500 according to the invention also comprises a common link 2. The common link 2 is a complex substantially planar part arranged with the closest manufacturing and assembly tolerances to the longitudinal axis L of the airflow control device 500 defined above, i.e. also substantially perpendicular to the rotation of the vanes 1i forming said set.

[0046] According to the invention, each vane 1i of the airflow control device 500 is connected at one of its ends in the longitudinal direction Li defined above to the frame 10 on the one hand to define a fixed rotation axis of the vane, and to a common link 2 on the other hand to generate a drive around a fixed rotation point. In this way, the movement of the common link 2 simultaneously generates a rotation of each vane 1i about its rotation axis with the same angular value.

[0047] 2 is a schematic perspective rear view of an airflow control device according to the present invention in a closed position. As shown, the frame 10 includes an integral support bar 50, e.g., injection molded as part of the frame 10, extending in a direction Vi perpendicular to the main extension direction Li of the vane 1.

[0048] 3 is a schematic front view of an airflow control device according to the invention in an open position. Each vane 1i includes a fin 11i. The fin 11i protrudes from the vane 1i, preferably perpendicular to its plane, by a distance that substantially corresponds to the distance between the vanes 1i in the open position. In other words, the vanes 1i have a height that corresponds to the vane pitch, while of course leaving enough space for the vanes to rotate between the open and closed positions. Such an arrangement reduces the vane oscillatory movement in the Vi direction in the open position.

[0049] 4 is a schematic perspective rear view of an airflow control device according to the present invention in an open position. In one option, the edges 13i of the fins 10i may be provided with vibration damping material 14i on one or both sides. An example of such a material may be rubber.

[0050] 5 shows a schematic diagram in a top view of an embodiment of an air flow control device according to the invention. The presence of a support bar 50 limits deformation due to pressure.

[0051] Figure 6 shows a perspective cross-sectional view of the airflow control device of Figures 1 and 2. The vane 1i has fins 11i configured to rest on the support bar 50 when the vane 1i is closed and subjected to pressure toward the support bar 50. In other words, the vane 1i deforms in a direction Ti perpendicular to the extension direction Vi of the support bar 50 and the extension direction Li of the vane 1i. The support bar 50 prevents the vane 1i from bending excessively.

[0052] The support bar 50 may be perforated (or have through holes) to limit pressure loss in the open position of the vanes.

[0053] The fins 11i may have a substantially triangular shape.

[0054] In another embodiment, the fins 11i may have a substantially semicircular shape.

[0055] Fig. 7 shows a partial cross-sectional view of the airflow control device of Fig. 2. The support bar 50 has a guide groove 52 extending along its length to receive the fin 11i at any position. In other words, the guide groove 52 extends along the Vi direction. The guide groove 52 receives the fin from three sides while leaving a small space 53 that allows the vane 1i to rotate smoothly. Effectively, any undesired movement of the vane 1i, especially during rotation, is limited. When pressure is applied to the vane 1i during the movement of the airflow control device 500, the vane 1i rests on the support bar 50 via the fin 11i.

[0056] 8a and 8b show an enlarged view of the upper part of the support bar 50. FIG. 8a exemplarily shows the device 500 without the vane 1i, and FIG. 8b shows the same part with the vane 1i properly in the open position. The frame 10 is provided with a support projection 17 at one end of the support bar 50. The support projection 17 protrudes most towards the nearest vane 1N, and thus is substantially adjacent to the vane 1N in its open position. In other words, the support projection 17 extends in the Vi direction, taking into account manufacturing tolerances, until it almost reaches or completely reaches the nearest, for example the last, vane 1N. As a result, in the open position, the nearest vane 1N is restricted from vibrating movement in the Vi direction.

[0057] The support bar 50 also includes a quarter-circular notch 55 in which the vane 1i is received and supported in the closed position, the notch 55 being shaped to guide the movement of the vane 1i toward the open position.

[0058] 9a and 10b are enlarged views of the lowermost part of the support bar 50. FIG. 9a exemplarily shows the device 500 without vanes 1i, and FIG. 9b shows the same part with vanes 1i appropriately in the open position. The frame 10 is provided with a support groove 18 at one end, e.g. the lowermost end, of the support bar 50. The support groove 18 is configured to receive the fin 11i of the nearest, e.g. the last vane 1i, taking into account manufacturing tolerances. As a result, in the open position, the nearest vane 1a is restricted from vibrating movements in the Vi direction and in the Li direction.

[0059] Generally, the integration of fins 11i on the rear side of vanes 1i working with support bars 50 integrated into the frame 10 provides pressure stiffness in the closed vane position, and vane-to-vane and vane-to-frame stiffness against vibration in the open vane position.

[0060] Figure 10 shows another embodiment of a vane 1i having multiple fins 11i, and Figure 11 shows an embodiment of an airflow control device 500 having the vane of Figure 10. The airflow control device 500 comprises multiple support bars 50, with the vane 1i having respective fins 11i adapted to operate with the support bars 50. Generally, the smaller the distance between the support bars 50, the less the vane 1 will deform.

[0061] Overall, the advantage of the present invention is that no additional support elements are required for the frame to ensure proper operation of the vanes in the open and closed positions and when switching between these positions. The vanes, which are slightly bent under pressure, can be held in the locked position by contact with the support bar. Furthermore, the assembly of the vanes to the frame can be performed in a single manufacturing step in the Ti direction only. Compared to designs with additional clamping and support bearings for the vanes, the reduced number of parts reduces the cost of the device and its manufacturing process. The reduced number of parts also eliminates the need for costly quality assurance devices and processes.

[0062] In one embodiment, the length of the vane covering the flow area is 600 mm when folding at 30 km / h. In such a case, the maximum allowable deformation in the Ti direction is 10 mm. Considering the maximum deformation of the vane under the folding pressure, it is necessary to have two support bars for each of the two fins in the vane.

[0063] The vanes may be constructed from PA-66, PP. The frame may be constructed from PP, Nylon, ABS.

[0064] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims

1. 1. An airflow control device for a front module of a motor vehicle, the control device comprising: a frame including an integral support bar; A plurality of vanes; Equipped with the plurality of vanes extend within and are rotatably mounted to the frame; Each vane is rotatable about an axis of rotation substantially parallel to a main direction of extension of each vane; the vane is rotatable between an open position and a closed position with the integral support bar extending in a direction perpendicular to the main extension of the vane; A control device, wherein each of the plurality of vanes has a fin configured to rest on the integral support bar when the vanes are closed and subjected to pressure toward the integral support bar.

2. The control system of claim 1 , wherein the fins project from the vanes a distance that substantially corresponds to the distance between the vanes in the open position.

3. the frame includes a support protrusion at one end of the integral support bar; The control device of claim 1 , wherein the support projection protrudes toward a nearest vane such that the support projection substantially abuts the nearest vane in the closed position.

4. the frame includes a support groove at one end of the integral support bar; The control device of claim 1 , wherein the support groove is configured to receive a fin of a nearest vane.

5. 2. The control device of claim 1, wherein the integral support bar has guide grooves extending along its length to receive fins at any position.

6. the support bar includes a quarter circular notch; The vane is received and supported in the notch in the closed position; The control device of claim 5 , wherein the notch has a shape that guides movement of the vane toward the open position.

7. The control device of claim 1 , wherein the support bar is perforated.

8. The control device of claim 1 , wherein the fin has a substantially triangular shape.

9. The control device of claim 1 , wherein the fin has a substantially semi-circular shape.

10. The control device of claim 1 , wherein the edges of the fins include a vibration dampening material.

11. The control device includes a plurality of support bars; The control device of claim 1 , wherein the vane includes a plurality of respective fins adapted to operate with the plurality of support bars.

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