Air Flap Device with Spring Assembly to Reduce Collision Noise
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Solution Overview
Problem
Air flap devices experience undesirable noise and mechanical stress due to random axial movements and collisions between the air flap and housing, which are exacerbated by production-related tolerances and differing thermal expansion coefficients.
Innovation Solution
Incorporating a spring assembly that absorbs axial movements of the air flap within its play relative to the housing, transforming kinetic energy into mechanical deformation, thereby reducing collisions and associated noise and stress. This can be achieved with Hookean springs pre-tensioning the air flap at mounting points, and optionally using a displaceable stop element to adjust and limit axial play.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If air flap is mounted with axial play to accommodate production tolerances and thermal expansion, then adaptability is improved, but noise emission and mechanical stress increase due to random axial movements and collisions
Solution Approach 1:
A spring assembly is pre-installed between the air flap and housing to provide cushioning before collisions occur. The spring absorbs axial movements and kinetic energy through elastic deformation, preventing direct metal-to-metal collisions between the air flap and housing, thereby reducing noise and mechanical stress while maintaining the necessary axial play for adaptability
Solution Approach 2:
The spring assembly acts as an intermediary element between the air flap and housing. It mediates the interaction by transforming the direct collision into a controlled elastic deformation process, allowing the system to accommodate thermal expansion and production tolerances while filtering out harmful vibrations and impacts
2Object-generated harmful factors
If spring assembly is added to reduce collisions and noise, then noise emission and mechanical stress are reduced, but device complexity increases
Solution Approach 1:
The spring assembly is applied locally only at the mounting points where axial collisions occur, rather than throughout the entire air flap structure. This localized approach addresses the specific collision problem at critical interfaces while keeping the rest of the结构简单, minimizing the increase in overall device complexity
3Loss of energy
If Hookean spring assembly is used to transform kinetic energy into mechanical deformation, then energy absorption is improved, but manufacturing precision requirements increase
Solution Approach 1:
The spring assembly parameters (wire diameter, coil diameter, number of turns, material properties) are specifically designed and selected to provide the optimal balance between energy absorption capability and tolerance to manufacturing variations. By carefully choosing spring constants and pre-compression values, the system achieves effective kinetic energy transformation while remaining robust to normal manufacturing precision variations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces noise emission and mechanical stress on the air flap and housing by absorbing kinetic energy through spring deformation, ensuring smoother operation and extended device lifespan.
Implementation Method 1
at least one part of the kinetic energy of the at least one air flap will be transformed into a mechanical deformation of the at least one spring assembly in the axial direction
Implementation Method 2
at least one part of the axial movement of the at least one air flap within its play relative to the housing in the direction of a first or/and second mounting point, which occurs against the increasing pre-tensioning effect of the at least one Hookean spring assembly
Data Source
AI summary
An air flap device comprises a housing with an air flow passage section. At least one air flap is mounted on a first and on a second mounting point on the housing. The second mounting point is located at an axial distance from the first mounting point. The air flap is rotatable around the pivot axis defining the axial direction. By pivoting the at least one air flap relative to the housing, the effective flow cross-section of the air flow passage section can be modified. The air flap(s) is mounted on the mounting points with an axial play relative to the housing. At least one spring assembly is arranged such that at least one part of an axial movement of the air flap(s) occurs within its play relative to the housing in the direction of the first or/and the second mounting point, against a pre-tensioning effect of the spring assembly.