An active grille shutter system

Abstract

An active grille shutter system (100) includes a frame (10), vanes (20), an actuator (30) and at least one linkage (40) Each vane (20) comprises mounting pins (22) and actuator pins (24). The mounting pins (22) rotatably support the vanes (20) and the actuator pins (24) facilitate movement of the vane (20) between a blocking configuration and an unblocking configuration. The vanes (20) are adapted to block air from reaching a heat exchanger (200) disposed downstream of the active grille shutter system (100) in the blocking configuration thereof. The actuator (30) is adapted to drive the at least one vane (20) through the linkage (40). The linkage (40) comprises apertures (42) to receive the actuator pins (24). The apertures (42) are of different configurations to control the interaction between the actuator pins (24) and the corresponding apertures (42) to controlling the movement of the vanes (20).

Description

[0001] TITLE

[0002] AN ACTIVE GRILLE SHUTTER SYSTEM

[0003] TECHNICAL FIELD

[0004] The present invention relates to a front end module of a vehicle, particularly, the present invention relates to an active grille shutter system.

[0005] BACKGROUND

[0006] An active grille shutter system 1 as illustrated in FIG. 1a includes a frame 2, a plurality of vanes 3, an actuator 4 and at least one linkage. The vanes 3 are disposed within the frame 2. Each vane 3 is rotatably supported by means of vane pins and adapted to move between a blocking configuration and an unblocking configuration. Specifically, the vane pins of the vanes 3 are received in corresponding holes 2a formed on central ribs 2b and sidewalls 2a of the frame 2 to rotatably support the vanes 3 between the sidewalls 2b. The central ribs 2b are spaced to define an actuator receiving space 4a for holding an actuator 4. In the blocking configuration, the vanes 3 are adapted to block air from reaching a heat exchanger disposed downstream of the active grille shutter system 1 . In the unblocking configuration, the vanes 3 are adapted to allow the air to flow across the active grille shutter system 1 to the heat exchanger. The actuator 4 is adapted to drive at least one vane 3 to cause movement of the vanes 3, particularly, angular movement of the vanes 3. The at least one linkage is functionally coupled to the actuator 4 and comprises a plurality of apertures to receive the vane pins of the corresponding vanes 3. The linkage is adapted to transmit drive from the actuator 4 to the at least one vane 2 through the vane pins interacting with the apertures. More specifically, a first vane pin of the vane 3 is rotatably received in the corresponding hole 2a formed on the frame 2 and a second vane pin is received in a corresponding aperture formed on the linkage for transmitting drive from the actuator 4 to the vane 3.

[0007] Generally, all the vanes 3 of the active grille shutter system 1 move together and by same angular displacement as illustrated in FIG. 1 b - FIG. 1d. FIG. 1 a illustrates the conventional active grille shutter system 1. FIG. 1 b illustrates the conventional active grille shutter system 1 with vanes 3 thereof in blocking configuration, particularly, vanes 3 aligned with respect to the axis a-a’. FIG. 1 c illustrates all vanes 3 moving simultaneously and at an angle of 45 degrees with respect to the axis a-a’. FIG. 1 d illustrates all vanes at angle of 90 degrees with respect to the axis a-a’ to define unblocking configuration thereof. Accordingly, the actuator has to provide higher operating torque, particularly, higher initial torque for moving the vanes, as the vane pins are constantly interacting with the corresponding apertures formed on the linkage. Further, the vanes are subjected to higher torques and are prone to mechanical failure causing reliability issues. Further, the linkages also subject to high stresses and mechanical failure. Sometimes, the vanes are required to be in different angular orientations to configure different vane openings for better control of air-flow to the heat exchanger and to enhance aesthetic appeal of the active grille shutter system. However, such arrangement for achieving different vane openings involve complex kinematics.

[0008] SUMMARY

[0009] An active grille shutter system is disclosed in accordance with an embodiment of the present invention. The active grille shutter system includes a frame, a plurality of vanes, an actuator and at least one linkage. The vanes are disposed within the frame. Each vane comprises mounting pins and actuator pins offset from the mounting pins. The mounting pins are for rotatably supporting the vanes and the actuator pins move the vane between a blocking configuration and an unblocking configuration. The vanes are adapted to block air from reaching a heat exchanger disposed downstream of the active grille shutter system in the blocking configuration thereof. The actuator is adapted to drive the at least one vane. The linkage functionally coupled to the actuator comprises a plurality of apertures to receive the actuator pins of the corresponding vanes. The linkage adapted to transmit drive from the actuator to the at least one vane. The apertures are of different configurations to control the interaction between the actuator pins and the corresponding apertures, thereby controlling the movement of the vanes. Generally, the apertures are of different shape and size and arranged in different orientations to delay the interaction between the actuator pins and the corresponding apertures.

[0010] Specifically, at least one of the apertures is oblong.

[0011] Further, at least one of the apertures follows a curved profile.

[0012] More specifically, at least one of the apertures is elliptical with major axis thereof being substantially parallel to longitudinal axis of the linkage.

[0013] Preferably, the apertures are elliptical with different major axis.

[0014] Generally, the active grille shutter system comprises separate linkages to transmit drive from the actuator to the corresponding vane and each linkage is formed with apertures of different configuration.

[0015] Further, the active grille shutter system comprises at least one connector cam adapted to configure connection between the actuator and the at least one linkage.

[0016] Specifically, the connector cam comprises a splined engagement element and a connector portion disposed on opposite sides of the connector cam. The splined engagement element is adapted to engage with the actuator and the connector portion is offset from the splined engagement element. More specifically, the linkage comprises a connector hole adapted to receive connector portion of the connector cam to configure functional coupling between the linkage and the actuator.

[0017] Generally, the connector hole is protruding sideways from one side of the linkage and is arranged between the apertures.

[0018] Specifically, at least one first aperture is formed on a first side of the connector hole and at least two, second apertures are formed on a second side of the connector hole opposite to the first side.

[0019] More specifically, at least one first aperture is of circular cross-section and adapted to securely receive actuator pin of one of the vanes, whereas the at least one second aperture is oblong adapted to loosely receive actuator pin of the corresponding other vanes.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Other characteristics, details and advantages of the invention may be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

[0022] FIG. 1 a illustrates a conventional active grille shutter system.

[0023] FIG. 1 b - FIG. 1 d illustrate schematic representations of the conventional active grille shutter system in different operating modes, particularly, blocking configuration, partially blocking configuration and unblocking configuration. FIG. 2a illustrates an isometric view of an active grille shutter system with vanes in blocking configuration.

[0024] FIG. 2b illustrates an isometric view of an active grille shutter system with vanes in partially blocked configuration.

[0025] FIG. 2c - 2e illustrate schematic representations of active grille shutter system in different operation modes, wherein in each mode the different vanes are at different angular orientations with respect to each other.

[0026] FIG. 3 illustrates an isometric view of an active grille shutter system without the vanes depicting linkage, cam connector and actuator.

[0027] FIG. 4 illustrates an isometric view of one of the vanes.

[0028] FIG. 5 illustrates an isometric view of the actuator of the active grille shutter system of FIG. 3.

[0029] FIG. 6 illustrates an isometric view of a connector cam adapted to configure indirect coupling between the actuator of FIG. 5 and the linkage.

[0030] FIG. 7 illustrates an isometric view of the linkage of the active grilles shutter system of FIG. 3.

[0031] FIG. 8 illustrates a top view of the linkage of FIG, 7.

[0032] FIG. 9 illustrates another isometric view of the linkage of FIG. 7. DETAILED DESCRIPTION

[0033] It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

[0034] The active grille shutter system includes a frame, a plurality of vanes, an actuator and at least one linkage. The vanes are disposed within the frame. Each vane comprises mounting pins and actuator pins offset from the mounting pins. The mounting pins are for rotatably supporting the vanes and the actuator pins transmit drive from the actuator to the vane to move the vane between a blocking configuration and an unblocking configuration. The vanes are adapted to block air from reaching a heat exchanger disposed downstream of the active grille shutter system in the blocking configuration thereof. The linkage is functionally coupled to the actuator and comprises a plurality of apertures to receive the actuator pins of the corresponding vanes. The linkage adapted to transmit drive from the actuator to the at least one vane. The apertures are of different configurations, particularly, of different shape, size and arranged in different orientations to delay the interaction between the actuator pins and the corresponding apertures, thereby controlling the movement of the vanes. Accordingly, the vanes of the active grille shutter system of the present invention can achieve different degree of opening. Particularly, the vanes of the active grille shutter system can be in different angular positions. Although, the present invention is explained with example of active grille shutter system for a vehicle, however, the present invention is applicable to any other fluid flow control device applicable in any vehicular and non-vehicular environment, wherein it is required to control movement of different vanes to achieve different degree of opening and closing of the vanes.

[0035] FIG. 2a and FIG. 2b illustrated an active grille shutter system 100 in accordance with an embodiment of the present invention in blocking and at least partially unblocking configuration respectively. In the blocking configuration, the active grille shutter system 100 is adapted to substantially prevent air-flow to a vehicle heat exchanger 200, such as for example, a radiator and a condenser disposed downstream of the active grille shutter system in the direction of the ram air. The active grille shutter system 100 includes a frame 10, a plurality of vanes 20, an actuator 30 and at least one linkage 40.

[0036] The frame 10 includes a pair of opposite sidewalls 10a and 10b and a pair of opposite longitudinal walls 10c and 10d interconnected with each other to define a closed rectangular profile as illustrated in FIG. 3. The frame 10 further includes a central web 10e adapted to centrally support the vanes 20 between the sidewalls 10a and 10b. The central web 10e and the sidewalls 10a and 10b further includes mounting holes 12a, 12b and 12e adapted to rotatably receive mounting pins 22 to rotatably support the vanes between the sidewalls 10a and 10b. The mounting pins 22 extend from opposite ends of the vanes 20 in opposite directions and along axis X of the vanes 20. The frame 10 further includes a back support either integrally formed there with or assembled thereto to provide back support to the vanes 20 and prevent bending of the vanes 20 as ram air strikes the vanes 20.

[0037] The vanes 20 are disposed within the frame 10. Particularly, the vanes 20 are rotatably supported between the sidewalls 10a and 10b and the central web 10e of the frame 10. The vanes 20 are adapted to angularly move to define blocking and unblocking configuration thereof. Each vane 20 comprises mounting pins 22 and actuator pins 24, in pairs, disposed at extreme ends thereof as illustrated in FIG. 4. Each vane 20 further includes a central portion 26 to centrally support the vane 20. The vane 20 further includes flaps 28 at extreme ends thereof and on both sides of the central portion 26 to prevent leakage between the vane 20 and the frame 10. The mounting pins 22 are received in the mounting holes 12a, 12b and 12e formed on the sidewalls 10a, 10b and the central web 10e to rotatably support the vane 20. The actuator pins 24 are offset from the mounting pins 22 and are functionally coupled to the actuator 30 to transmit drive from the actuator 30 to the vane 20 to facilitate movement of the vane 20 between a blocking configuration and an unblocking configuration. In the blocking configuration, the vanes 20 are adapted to block air from reaching a heat exchanger 200 disposed downstream of the active grille shutter system 100. In the unblocking configuration, the vanes 20 adapted to allow air to cross the active grille shutter system 100 and reach the heat exchanger 200 disposed downstream of the active grille shutter system 100.

[0038] The actuator 30 adapted to drive at least one vane 20. The actuator 30 is either centrally mounted or side mounted on the frame 10 of the active grille shutter system 100. FIG. 8 illustrates an isometric view of the actuator 30. The actuator 30 comprises an engagement means, for example, an engagement hole 32, particularly, a splined hole. The splined hole 32 receives a splined engagement element 52 of a connector cam 50 that in turn is connected to the linkage 40 to transmit drive from the actuator to the linkage 40.

[0039] The at least one linkage 40 is functionally coupled to the actuator 30. The linkage 40 is connected to the actuator 30 either directly or indirectly. Particularly, the linkage 40 is indirectly coupled to the actuator 30 through the connector cam 50. More specifically, connector cam 50 configures connection between the actuator 30 and the linkage 40 to transmit drive from the actuator 40 to the vane 20 through the linkage 40. The connector cam 50 is adapted to provide mechanical advantage while transmitting the drive from the actuator 30 the linkage 40. FIG. 6 illustrates an isometric view of the connector cam 50. More specifically, the connector cam 50 comprises the splined engagement element 52 and a connector portion 54 disposed on opposite sides thereof. The splined engagement element 52 is adapted to engage with the actuator 30, particularly, the splined engagement element 52 is a splined shaft received in the splined hole 32. The connector portion 54 is offset from the splined engagement element 52 and is adapted to be received in a connector hole 44 formed on the linkage 40 to transmit drive from the actuator 30 to the linkage 40. The connector hole 44 formed on the linkage 30 is adapted to receive connector portion 54 of the connector cam 50 to configure functional coupling between the linkage 40 and the actuator 30 through the connector cam 50. The linkage 40 comprises a plurality of apertures 42 to receive the actuator pins 24 of the corresponding vanes 20. More specifically, the number of apertures 42 on the linkage 40 corresponds to the number of vanes 20. With such arrangement, linkage 40 is functionally coupled to the vanes 20 directly and transmits drive from the actuator 30 to the vanes 20 via the connector cam 50. More specifically, the linkage 40 causes the angular movement of the vanes 20 based on angular movement of the linkage 40 by the connector cam 50. The direct connection between the linkage 40 and the vanes 20 reduces the number of parts, improves reliability, and results in improved control on vane movement. Such arrangement results in simpler arrangement for drive transmission from the actuator to the vanes 20 and tooling costs are reduced. The linkage 40 is adapted to transmit drive from the actuator 30 to the at least one vane 20 based on the interaction between the apertures 42 formed on the linkage 40 and the actuator pins 24 of the corresponding vanes 20. The apertures 42 are of different configurations to control the interaction between the actuator pins 24 and the corresponding apertures 42, thereby controlling the movement of the vane 20. More specifically, the apertures 42 are of different shape and size and arranged in different orientations to delay the interaction between the actuator pins 24 and the corresponding apertures 42 to control the degree of opening and closing of the vanes 20. More specifically, the vanes 20 are at different angular orientations with respect to the central axis A-A’ in a particular mode of operation of the active grille shutter system 100. FIG. 2c illustrates the active grille shutter system 100 in blocking configuration with all vanes 20 thereof in blocking configuration, particularly, all vanes 20 aligned with respect to the axis A-A’. FIG. 2d illustrates the active grille shutter system 100 in partially unblocking configuration, with all vanes 20 at different angles a1 , a2, a3 with respect to the axis A-A’. More specifically, first vane 20 is at angle of 45 degrees with respect to the axis A-A’, whereas remaining vanes 20 are at different angles, less than 45 degrees, particularly, the remaining vanes 20 are at 30 degrees and 15 degrees with respect to the axis A-A’ respectively. FIG. 2e illustrates all vanes 20 in unblocking configuration, with all vanes 20 at different angles (31 , [32, [33 with respect to the axis A-A’. More specifically, first vane 20 is at angle of 90 degrees with respect to the axis A-A’, whereas remaining vanes 20 are at different angles, less than 90 degrees, particularly, the remaining vanes 20 are at 75 degrees and 60 degrees with respect to the axis A-A’ respectively. The connector hole 44 formed on the linkage 40 is protruding sideways from one side of the linkage 40 and is arranged between the apertures 42. More specifically, at least one first aperture 42a is formed on a first side of the connector hole 44 and at least two second apertures 42b and 42c respectively are formed on a second side of the connector hole 44 opposite to the first side. In accordance with a preferred embodiment, the connector hole 44 is disposed between the first circular aperture 42a and the second elliptical aperture 42b. However, the present invention is not limited to any particular configuration and placement of the connector hole 44 as far as the connector hole 33 is capable of securely receiving the connector portion 54 for configuring functional coupling between the connector cam 50 and the linkage 40. Accordingly, the connector cam 50 is capable of transmitting drive from the actuator 30 to the linkage 40.

[0040] Generally, at least one of the apertures 42 is oblong. Specifically, at least one of the apertures 42 is elliptical. More specifically, the apertures 42 are elliptical with different major axis being substantially parallel to longitudinal axis of the linkage 40. In accordance with a preferred embodiment of the present invention, the first aperture 42 is circular and the remaining apertures 42b and 42c are elliptical, wherein major axis of the remaining apertures 42b and 42c is increasing with distance from the first aperture 42a. In accordance with an embodiment, the remaining apertures 42b and 42c are oblong and follow a curved profile. More specifically, the major axis of the third elliptical aperture 42c is more than the major axis of the second elliptical aperture 42b. The first aperture 42a is of circular cross-section and adapted to securely receive actuator pin 24a of one of the vanes 20a, whereas the at least one second aperture 42b, 42c is oblong adapted to loosely receive actuator pin 24b, 24 of the corresponding other vanes 20b, 20c. Such configuration of the apertures 42 of different shape, size and arrangement of the apertures 42 on the linkage facilitates in controlling the opening and closing of the vanes for achieving different degree of opening and closing of the vanes instead of simultaneous moving of the vanes by same degree in case of conventional active grille shutter system. The present invention is not limited to any particular configuration, placement and number of the apertures as far as the apertures are capable of controlling interaction between the apertures 42 and the actuator pins 24 of the vanes 20 to regulate the opening and closing of the vanes 20. Such configuration of the linkage 40 of the active grille shutter system 100 of the present invention provides improved control over movement of the vanes 20 between blocking and unblocking configuration thereof, thereby providing improved flow control across the active grille shutter system 100. Such configuration of the linkage with different configuration of the apertures 42 also reduces the initial torques required for opening and closing of the vanes 20 and stresses on the various elements transmitting drive from the actuator 30 to the vanes 20, thereby improving the reliability and the service life of such elements.

[0041] The degree of opening and closing of the vanes 20 can be controlled by other ways also. Specifically, the different vanes 20 can be moved by different linkages 40 deriving motion from a common actuator 30. More specifically, separate linkages 40 can be used to transmit drive from the common actuator 30 to the corresponding vanes 20 and each linkage 40 can be formed with apertures 42 of different configuration.

Claims

WE CLAIM:1 . An active grille shutter system (100) comprising:• a frame (10);• a plurality of vanes (20) disposed within the frame (10), each vane (20) comprise mounting pins (22) and actuator pins (24) to rotatably support the vane (20) and move the vane (20) between a blocking configuration and an unblocking configuration, the vanes (20) adapted to block air from reaching a heat exchanger (200) disposed downstream of the active grille shutter system (100) in the blocking configuration thereof;• an actuator (30) adapted to drive at least one vane (20);• at least one linkage (40) functionally coupled to the actuator (30) and comprising a plurality of apertures (42) to receive the actuator pins (24) of the corresponding vanes (20) and adapted to transmit drive from the actuator (30) to the at least one vane (20); characterized in that the apertures (42) are of different configurations to control the interaction between the actuator pins (24) and the corresponding apertures (42), thereby controlling the movement of the vane (20).

2. The active grille shutter system (100) as claimed in the previous claim, wherein the apertures (42) are of different shape and size and arranged in different orientations to delay the interaction between the actuator pins (24) and the corresponding apertures (42).

3. The active grille shutter system (100) as claimed in any of the preceding claims, wherein at least one of the apertures (42) is oblong.

4. The active grille shutter system (100) as claimed in any of the preceding claims, wherein at least one of the apertures (42) follows a curved profile.

5. The active grille shutter system (100) as claimed in any of the preceding claims, wherein at least one of the apertures (42) is elliptical with major axis thereof being substantially parallel to longitudinal axis of the linkage (40).

6. The active grille shutter system (100) as claimed in any of the preceding claims, wherein the apertures (42) are elliptical with different major axis.

7. The active grille shutter system (100) as claimed in any of the preceding claims comprises separate linkages (40) to transmit drive from the actuator (30) to the corresponding vane (20) and each linkage (40) is formed with apertures (42) of different configuration.

8. The active grille shutter system (100) as claimed in any of the preceding claims further comprises at least one connector cam (50) adapted to configure connection between the actuator (30) and the at least one linkage (40).

9. The active grille shutter system (100) as claimed in the previous claim, wherein the connector cam (50) comprises a splined engagement element (52) and a connector portion (54) disposed on opposite sides thereof, the splined engagement element (52) is adapted to engage with the actuator (30) and the connector portion (54) is offset from the splined engagement element (52).

10. The active grille shutter system (100) as claimed in the previous claim, wherein the linkage (40) comprises a connector hole (44) adapted to receive connector portion (54) of the connector cam (50) to configure functional coupling between the linkage (40) and the actuator (30).11 . The active grille shutter system (100) as claimed in the previous claim, wherein the connector hole (44) is protruding sideways from one side of the linkage and is arranged between the apertures (42).

12. The active grille shutter system (100) as claimed in the previous claim, wherein at least one first aperture (42a) is formed on a first side of the connector hole (44) and at least two second apertures (42b) and (42c) are formed on a second side of the connector hole (44) opposite to the first side.

13. The active grille shutter system (100) as claimed in the previous claim, wherein the at least one first aperture (42a) is of circular cross-section and adapted to securely receive actuator pin (24a) of one of the vanes (20a), whereas the at least one second aperture (42b, 42c) is oblong adapted to loosely receive actuator pin (24b, 24) of the corresponding other vanes (20b, 20c).

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