Modifiable active grille shutter

Abstract

An active grille structure. The structure includes a center framing common portion which includes a modular vane structure that can be removed and substituted for another structure. At least one outer peripheral attachable active air frame valance is selectively attachable on the sides of the frame for matching the appearance of a predetermined vehicle. Thus, the modular vane structure has a 3-dimensional appearance formed by compression injection molding of a clear polycarbonate. The clear polycarbonate components are coated on the back side thereof to provide the desired appearance across the frame valances, vanes and center portion.

Description

[0001] MODIFIABLE ACTIVE GRILLE SHUTTER

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a modifiable active grille shutter which can be used in a multitude of vehicles.

[0004] BACKGROUND OF THE INVENTION

[0005] Active front grille structures have been used in recent vehicles to provide improved aerodynamics to vehicles and also provide improved modulation of airflow to the vehicles’ cooling system. This provides for efficiencies which add to the vehicle’s range and performance.

[0006] Typically, active grille structures include a series of moveable vanes which move in response to vehicle controls to open or close a series of vanes on the grille. Examples of such structures are found in co-assigned U.S. patent nos. 9,694,669, 10,766,356, and 11 ,065,952. Typically, such structures are vehicle program-specific and designed for use in a particular vehicle trim level. Therefore, such structures do not have cross-platform applicability and are somewhat costly to produce.

[0007] Additionally, the designs are more functional than aesthetically pleasing. Contoured and design-oriented active grille structures have been somewhat hard to produce because of the necessary functionality of these grilles.

[0008] Therefore, it is a goal to provide a grille structure that can be used in various vehicles and customized to various vehicle designs while maintaining functionality of the active common active grille structure.

[0009] SUMMARY OF THE INVENTION

[0010] An active grille structure. The structure includes A center framing common portion which includes a modular vane structure that can be removed and substituted for another structure.

[0011] At least one outer peripheral attachable active air frame valance is selectively attachable on the sides of the frame.

[0012] Thus, the modular vane structure has a 3-dimensional appearance formed by compression injection molding of a clear polycarbonate. The clear polycarbonate is coated on the back side thereof to provide an opaque vane structure with a textured appearance but having a sooth outer face for sealing purposes. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0015] Figure 1 is a rear view of a grille made in accordance with the teachings of the present invention;

[0016] Figure 2a is the view of Figure 2 illustrating the common frame used in the grille along with a first alternative side frame valance made in accordance with the teachings of the present invention;

[0017] Figure 2b is the view of Figure 2 illustrating the common frame used in the grille along with a second alternative side frame valance made in accordance with the teachings of the present invention;

[0018] Figure 3 is a view similar to Figure 1 highlighting the common area of the present invention;

[0019] Figure 3a is the view of Figure 2 illustrating the common frame used in the grille along with a first alternative side frame valance made in accordance with the teachings of the present invention;

[0020] Figure 3b is the view of Figure 2 illustrating the common frame used in the grille along with a second alternative side frame valance made in accordance with the teachings of the present invention;

[0021] Figure 4 is a side sectional view of a moveable vane of the present invention showing the paint film coating on the rear surface of the vane;

[0022] Figure 5 is a side sectional view of a moveable vane of the present invention showing the paint film coating on the rear surface of the vane; and

[0023] Figure 6 is a view showing examples of various styles of aesthetically diverse outer grille surfaces which can be produced in accordance with the teachings of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] The following description of the preferred embodiments are merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0025] Referring now to the drawings in accordance with the present invention there is provided an active grille structure generally shown at 10. The structure 10 includes a center framing common portion 12 which includes a modular vane structure insert 14 that can be removed and substituted for another structure. At least one outer peripheral attachable active air frame valance 16 is selectively attachable on the sides of the frame 16. Thus, the grille structure 10 formed by the modular vane structure has a 3-dimensional appearance 19 formed by compression injection molding of a clear polycarbonate 18. The clear polycarbonate 18 is coated on the back side 20 thereof with a coating 22 to provide an opaque vane structure.

[0026] The active air frame 12 is selected to match the vehicle it is to be installed in. The modular frame structure insert 14 is selected from a suitable vehicle matching insert containing features such as a moveable door, a textured member, a vertical louver member, a horizontal louver member or an angled louver member. Examples of various final active grilles structures may be employed. Typically, the common portion 12 includes an active vane includes a modular frame active grille structure 11 which holds the vanes in a frame 13. The frame includes a motor 15 and an actuator 17 for moving the vane in response to predetermined vehicle operating conditions such as speed, temperature, sensed engine parameters and the like. Thus, the combination of the modular vane structure and active air frame is preselected for stylistically matching of the aesthetics of a vehicle. Modular frame structures of the like wherein the present vanes are useful are set forth in co-assigned U.S. Patent Nos.9, 694, 669; 10,766,635; and 11 ,065,952 the teachings of which are incorporated by reference of these patents into the specification herein.

[0027] Similarly, the side valances 16 are also selected from appearance matching members 16A or 16B or another design matching the styling required for a particular application and are attached to provide proper appearances for their respective fascia assemblies.

[0028] In the present invention, the active grille structure includes vanes made of a clear polycarbonate 18. The back 20 of said clear polycarbonate vane 18 is coated with a paint film or other coating 22 to provide a color matching or color-controlled surface. While a paint film is preferred other coatings could also be used to provide an opaque blade or a semitransparent blade or a transparent blade. In a preferred embodiment the blade is injection compression molded and the paint film used is at least partially transparent. The outside show surfaces of the blade include a flat-type glare-free surface which can either be formed during molding of the polycarbonate or can be supplied by coating of the polycarbonate with a clear flat paint coating 24. The outer show surface of the vane is formed in a 3-dimensional pattern for forming the final stylistic design of the grille. The partially transparent film allows light to go through the film but appears opaque in the absence of light being transmitted through the film.

[0029] Injection Compression molding (ICM) enables molding of a large clear part such as a vane of variable thickness without presenting flow lines or stress marks using a lower tonnage press.

[0030] The use of ICM in the present invention offers: 1 ) Optimized visual aspect; 2) Minimized deformation after cooling; and 3) Lower clamping force.

[0031] In a preferred embodiment the molded polycarbonate part which is thereafter hard-coated with polysiloxane 24 that protects the polycarbonate part thereby providing the longest weathering and superior abrasion resistance.

[0032] A special clear primer system 26 is available from Magna LexaMar, Michigan U.S that allows for the paint to adhere on the hard-coated surface.

[0033] The polycarbonate surface after being hard coated with siloxane obtains a glasslike behavior with superior abrasion resistance thus adhesion over this type of surface is very challenging.

[0034] In an alternate embodiment a paint film is molded in place to create textures on the front or back of the vanes, the common framing or the end valances 16A, 16B. In this embodiment. The film can be attached to the vanes or outer structure to simulate a 3-dimensional surface to the part. In an alternate embodiment a show surface can be presented on the part via a paint layer.

[0035] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMSWhat is claimed is:1 . An active grille structure comprising: a center framing common portion which includes a modular vane structure that can be removed and substituted for another structure; and at least one outer peripheral attachable active air frame valance which is removable and replaceable for providing a custom appearance when used in a predetermined vehicle.

2. The active grille structure of claim 1 wherein the modular vane structure includes an active grille structure which has vanes actuated by a motor and actuator.

3. The active grille structure of claim 2 wherein there are a pair of active grille structures.

4. The active grille structure of claim 2 wherein the modular grille structure is coated using a paint film.

5. The active grille structure of claim 4 wherein the paint film forms a 3- dimensional surface appearance.

6. The active grille structure of claim 1 wherein said modular vane structure has a 3-dimensional surface formed on a first side, the 3-dimensional surface is formed by injection compression molding of a clear polycarbonate and wherein said clear polycarbonate is coated on a back side thereof to provide an opaque vane structure.

7. The active grille structure of claim 6 wherein the active air frame is selected from the group of a frame containing a moveable door, a textured member, a vertical louver member, a horizontal louver member or an angled louver member.

8. The active grille structure of claim 1 wherein the combination of the modular vane structure and active air frame is preselected for stylistically matching of the aesthetics of a vehicle.

9. The active grille structure of claim 6 wherein the back of said clear polycarbonate vane is coated with a paint film.

10. The active grille of claim 9 wherein the paint film is selected from an opaque or at least partially transparent film.11 . The active grille of claim 8 wherein the partially transparent film allows light to go through the film but appears opaque in the absence of light being transmitted through the film.

12. The active grille of claim 6 wherein the polycarbonate outer show surface is coated with a flat clear outer coating or film.

13. The active grille of claim 12 wherein the flat clear outer coating is a polysiloxane clear coating.

14. The active grille of claim 13 wherein a clear primer is used on the polycarbonate prior to applying the polysiloxane coating.

15. An active grille structure comprising: a center framing common portion which includes a modular vane structure that can be removed and substituted for another structure; at least one outer peripheral attachable active air frame; wherein said modular vane structure has a first side and an outer show surface side; a 3-dimensional surface is formed on said first side, the 3-dimensional surface is formed by injection compression molding of a clear polycarbonate and wherein said clear polycarbonate is coated on at least a first side thereof to provide an opaque vane structure; and said vane being coated with a clear primer and a clear siloxane is used for coating the part and providing a final paint adherent finish, wherein the part is clear to the outer show surface side and the visual appearance is of the 3-dimensional surface of the first side.

16. The active grille structure of claim 15 wherein an alternate outer peripheral valance is attached to change the appearance of the active grille structure.

17. The active grille structure of claim 16 further comprising a replaceable center portion of the center framing common portion for changing the appearance of the active grille structure.

18. The active grille structure of claim 15 wherein the center framing portion includes an outer peripheral frame and a central portion, the outer peripheral frame including a first vane holding structure on a first side and a second vane holding structure on a second side, the central portion including an actuator and a linkage for opening and closing multiple vanes of the modular vane structure.

19. The active grille structure of claim 18 wherein said actuator is a motor.

20. The grille structure of claim 19 wherein the vane structure is multiple hangar door style vanes.

21. The active grille structure of claim 15 wherein the center portion and the outer peripheral frame are made by injection compression molding of a clear polycarbonate material. With a textured surface on a first side and an outer show surface on a second side, the side is coated with an opaque coating such that the outward appearance is of a textured material.

22. The active grille structure of claim 21 wherein the second side is coated with a clear siloxane material.

23. The active grille structure of claim 23 where in a clear primer is used for priming the polycarbonate prior to coating with the siloxane material.

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