Vehicle Front End Air Flap Support Element Design
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Solution Overview
Problem
Existing vehicle front end designs face issues with high assembly and manufacturing costs, complex component configurations, and reduced airflow area due to the need for numerous components and undercuts in the slat support system, which can lead to bending and damage under wind loads.
Innovation Solution
A vehicle front end design featuring support elements with offset support projections that act as pivot bearings, allowing for a one-piece frame and support element production without undercuts, using injection molding, and minimizing components, with reinforcing ribs for enhanced load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional slat support systems with multiple components and bearings are used, then the slats can be mounted pivotably, but the assembly complexity and manufacturing costs increase significantly
Solution Approach 1:
The support element integrates multiple functions into a single component: it provides structural support, houses the bearing function through an integrated bore, and enables pivotable mounting of slats. This merging of support and bearing functions eliminates the need for separate bearing components and reduces assembly complexity.
Solution Approach 2:
The support element serves multiple purposes simultaneously: it acts as a structural support member, provides pivot bearings through integrated bores, and enables adjustable positioning of slats. This multi-functionality reduces the total number of components needed in the system.
2Strength
If additional bearing components are added to support slats under wind loads, then the slats can be supported against bending, but the manufacturing costs and assembly efforts increase
Solution Approach 1:
The support element combines structural support and bearing functions in one integrated component, eliminating the need for additional bearing parts while maintaining the ability to support slats under wind loads.
Solution Approach 2:
The support element is manufactured using injection molding, creating a composite structure that integrates rigid support sections with bearing bores, achieving both strength and rotational capability in a single molded part.
3Reliability
If numerous components and undercuts are used in the slat support system, then the slats can be securely mounted, but the airflow area is reduced and the design becomes more complex
Solution Approach 1:
The support element merges multiple support and mounting functions into a single streamlined component, reducing the number of separate parts and minimizing interference with airflow while maintaining secure slat mounting.
4Strength
If traditional multi-component support systems are used, then the slats can be supported against wind loads, but the assembly and manufacturing efforts increase
Solution Approach 1:
The support element integrates support and bearing functions in one component, reducing the number of assembly steps and operations required while maintaining the ability to support slats against wind loads.
Solution Approach 2:
The support element performs multiple functions simultaneously - structural support, bearing, and positioning - which reduces the total number of components to be assembled and improves assembly efficiency.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The vehicle front end has a cooler area and an air flap device that is arranged in front of the cooler area. The air flap device has a frame (1) and a lamella that is pivoted for regulating the air inlet. The supporting elements (3) have supporting projections (3a,3b,3c), which are arranged such that the projections lie against a contact area on inner side of the lamella or lie against a driving direction (X) on the lamella. The supporting projections have contact sections for contacting to the contact area of the lamella.