Vehicle Air Guiding Element Stabilization via Foam Crash Element

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Solution Overview

Problem

The existing rigid air guiding elements in motor vehicle front modules, made from filled plastic, are heavy and do not provide optimal pedestrian protection, especially in leg impacts, due to their lack of flexibility.

Innovation Solution

An air guiding element is attached to a foam crash element using fastening lugs with integral hinges, allowing for dimensional and positional stabilization with softer, unfilled plastic materials, enhancing pedestrian protection by enabling the use of lighter and more flexible components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a relatively rigid filled plastic material is used for the air guiding element, then dimensional and positional stability is achieved, but pedestrian protection is worsened due to lack of flexibility and increased weight

Engineering Contradiction:

Improvedimensional and positional stabilityVSAvoidpedestrian protection

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The air guiding element is divided into multiple components: the main body made of softer unfilled plastic and rigid reinforcement elements (such as ribs, stiffening structures, or integrated metal inserts) positioned strategically to provide dimensional and positional stability only where necessary. This segmentation allows the majority of the component to be flexible for pedestrian protection while maintaining stability in critical areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The air guiding element uses composite construction combining softer unfilled plastic material with rigid reinforcement elements. This composite approach enables the base material to provide flexibility and pedestrian protection while the reinforcement structures contribute dimensional and positional stability, resolving the contradiction between softness and stability.

Inventive Principle:

Principle #40Composite materials

2Strength

If a relatively rigid filled plastic material is used for the air guiding element, then structural strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidweight of air guiding element

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The air guiding element structure is segmented into lightweight unfilled plastic components and strategically placed rigid reinforcement elements. This segmentation eliminates the need for fully dense filled plastic throughout the entire component, reducing overall weight while maintaining structural strength in critical load-bearing areas through the reinforcement elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite construction combines lightweight unfilled plastic with high-strength reinforcement materials positioned where structural integrity is most needed. This approach achieves the required structural strength without the penalty of using heavy filled plastic throughout the entire air guiding element, thereby reducing overall weight.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If a softer unfilled plastic material is used for the air guiding element, then pedestrian protection is improved through increased flexibility, but dimensional and positional stability deteriorates

Engineering Contradiction:

Improvepedestrian protectionVSAvoiddimensional and positional stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The air guiding element is segmented into a flexible main body made of softer unfilled plastic for pedestrian protection and separate rigid reinforcement elements or structures that provide dimensional and positional stability. The segmentation allows each zone to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite material approach uses softer unfilled plastic as the base material for pedestrian protection while incorporating rigid reinforcement structures within or attached to the air guiding element. This composite construction ensures that the softer material provides flexibility for safety while the rigid components maintain dimensional and positional stability.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9376087B2Front module of a motor vehicle

Publication Date: 2016.06.28 DR ING H C F PORSCHE AG

AI summary

A front module (7) of a motor vehicle has vehicle front-side air guiding element (1) for a vehicle radiator, and has a foam crash element (6) that is positioned in front of the air guiding element (1) on the front side. The air guiding element (1) is fastened to the foam crash element (6) at least in a part region. The front module ensures particularly satisfactory dimensional and positional stabilization of the air guiding element (1).