Air Inlet Grille Sensor Support Integration
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Solution Overview
Problem
The integration of parking assistance sensors into motor vehicle air intake grilles is complex and costly, often requiring specific grilles for vehicles with and without this feature, compromising aesthetics and increasing production costs.
Innovation Solution
An air intake grille design where a sensor support element is integrated by fixing it to existing decorative elements and the frame, allowing for optional inclusion or exclusion without altering the grille's aesthetics or production costs, using a method that involves cutting and reconfiguring existing decorative elements and fixing lugs to attach a support element that can be welded in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a specific grille integrating a sensor support is created, then the sensor integration is achieved, but the production cost increases and a single grille design cannot be used for vehicles with or without parking assistance function
Solution Approach 1:
The grille is divided into modular components: a base grille structure and separate sensor support elements. The sensor support element can be independently attached to the base grille, allowing the grille to be configured for vehicles with or without parking assistance function. This segmentation enables a single base grille design to serve multiple vehicle configurations.
Solution Approach 2:
The base grille design is made universal by incorporating attachment means that can accommodate sensor support elements when needed, while maintaining functionality for vehicles without sensors. The same base grille serves dual purposes: as a standalone decorative and functional component, or as a platform for sensor integration, eliminating the need for different grille designs.
2Adaptability or versatility
If a specific grille integrating a sensor support is created, then the sensor integration is achieved, but the production cost increases
Solution Approach 1:
By segmenting the grille into a base structure and detachable sensor support elements, the manufacturing process is simplified. The base grille can be mass-produced using standard processes, and sensor support elements are added only when required, avoiding the need to produce expensive custom-integrated grilles for every vehicle.
Solution Approach 2:
A single universal base grille design is manufactured for all vehicles, reducing tooling and production setup costs. The grille serves multiple functions depending on configuration: vehicles without sensors receive the base grille alone, while vehicles with parking assistance receive the base grille with attached sensor support elements, all from the same production line.
3Reliability
If multiple fixing parts are used to fix a sensor support to the grille, then the sensor support is secured, but the aesthetics are reduced and the mounting becomes complicated
Solution Approach 1:
The attachment means are integrated into the decorative elements of the grille itself, merging the functional fixation components with the aesthetic decorative components. This integration ensures that the fixing mechanism is structurally sound while remaining visually concealed or harmonious with the grille's design, avoiding the appearance of separate, bulky fixing parts.
Solution Approach 2:
The sensor support element acts as an intermediary component that bridges the base grille and the sensor. It provides multiple attachment points for secure fixation while maintaining a sleek, integrated appearance that preserves the grille's aesthetics. The element is designed to be visually compatible with the grille's decorative style.
4Reliability
If multiple fixing parts are used to fix a sensor support to the grille, then the sensor support is secured, but the mounting becomes complicated
Solution Approach 1:
The attachment means are combined into a pre-assembled sensor support element that attaches to the base grille as a single unit. This reduces the complexity of mounting operations, as the sensor support element with its integrated fixing mechanisms can be installed in one operation rather than requiring multiple separate fixing steps.
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
Enables simple and aesthetic integration of sensor supports, maintaining a single grille design for vehicles with or without parking assistance functions, reducing production costs and complexity while maintaining aesthetic appeal.
Implementation Method 1
the support element is welded to the air inlet grille
Data Source
Figure 1
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AI summary
The grid (1) has a frame (2) and a set of decoration elements (6) that is attached to each other and to the frame by mounting legs (16). The set of decoration elements extends approximately transversely across the frame, and defining a set of passage openings (14) for passage of air. The frame, the decoration elements, and the legs are manufactured from only one part. A sensor support element (22) is fixed on the grid. The support element is fixed to the mounting leg extending from the decoration element and/or starting from the frame. An independent claim is also included for a method for manufacturing an air intake grid.