Active Air Flap Structure for Flush Grille Airflow Control
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Solution Overview
Problem
Existing active air flaps for vehicles generate wind noise and reduce aesthetic quality due to a step formed between the flap member and the grill, and inefficiencies in opening and closing the air inlet lead to increased air resistance and decreased fuel efficiency, especially when traveling at high speeds.
Innovation Solution
An active air flap apparatus with a frame coupled to the rear surface of the grill, featuring a lower and upper flap member with inclined upper ends and a link member connecting them to an actuator, which allows for efficient opening and closing of the air inlet without a step, reducing air resistance and wind noise by guiding airflow and minimizing the load on the flap member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flap member is mounted on the rear surface of the grill, then the air inlet can be opened and closed to control airflow, but a step is formed between the flap member and the air inlet due to the thickness of the grill, causing wind noise and reducing aesthetic quality
Solution Approach 1:
The patent moves the mounting location of the flap member from the rear surface of the grill to the front surface of the grill. This dimensional change in mounting position eliminates the step formation caused by grill thickness, as the flap member now rotates on the same surface plane as the air inlet opening, thereby reducing wind noise and improving aesthetic quality while maintaining air inlet control functionality
Solution Approach 2:
The patent creates a recess in the front surface of the grill that mirrors the shape and size of the flap member when closed. This recess allows the flap member to sit flush with the front surface, eliminating the step effect without requiring changes to the grill thickness or flap member design, thus reducing wind noise while preserving the air inlet control function
2Ease of operation
If the flap member is mounted on the rear surface of the grill, then the air inlet can be opened and closed, but the step formed causes degraded aesthetic quality in the appearance of the grill
Solution Approach 1:
The patent changes the mounting dimension from rear surface to front surface of the grill. This allows the flap member to be positioned on the visible front surface, eliminating the step gap that degrades aesthetic quality, while the air inlet control function remains intact through the flap member's rotation mechanism
Solution Approach 2:
The recess created in the front surface of the grill copies the contour of the closed flap member, allowing it to sit perfectly flush with the surrounding surface. This eliminates visual discontinuities and maintains smooth aesthetic appearance while preserving the operational air inlet control capability
3Strength
If a rib is formed between the upper end of the flap guard portion and the flap fixing portion, then structural support is provided, but air resistance is generated and load is created on the rotational force of the flap member
Solution Approach 1:
The patent removes the rib structure that was previously formed between the upper end of the flap guard portion and the flap fixing portion. By extracting this protruding element, the source of air resistance and additional rotational load is eliminated, while alternative structural support is provided through the overall flap member design and mounting configuration
Solution Approach 2:
Instead of adding a rib protrusion to provide structural support, the patent inverts the approach by creating a recessed design where the flap member integrates smoothly with the grill surface. The structural support function is achieved through the recess geometry and mounting framework rather than through protruding rigid elements, thereby reducing air resistance
4Loss of energy
If the flap member closes the air inlet at high speed, then fuel efficiency is improved by reducing air resistance, but the step and rib cause increased air resistance and reduced fuel efficiency
Solution Approach 1:
By relocating the flap member mounting from the rear surface to the front surface of the grill, the patent eliminates the step formation that creates turbulent airflow and additional air resistance. This dimensional change allows the flap to close more smoothly against the grill face, reducing energy loss from air resistance and improving fuel efficiency
Solution Approach 2:
The recess in the front surface of the grill copies the flap member's closed position geometry, enabling a flush fit that eliminates step-induced turbulence. This allows the air inlet to close more effectively without creating additional air resistance, thereby reducing energy loss and improving fuel efficiency when traveling at high speeds
Data Source
AI summary
The present disclosure relates to a technology for reducing air resistance when a vehicle travels or cooling the inside of an engine room by being coupled to an air inlet of a grill. An active air flap apparatus for a vehicle includes a frame coupled to a rear surface of a grill, a lower flap member and an upper flap member each having rotatably fixed to the frame to open or close an air inlet disposed in the grill, and a link member connecting the lower flap member to an actuator to open or close the air inlet, in which upper ends of the lower flap member and the upper flap member are inclined in a rearward direction of the vehicle.