Air Intake Regulator Frame With Elastic Tabs for Flap Assembly
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Solution Overview
Problem
Existing air intake control devices for motor vehicle engines face issues with manufacturing tolerances and clearance variations leading to excessive deformation or breakage of movable shutters during assembly, due to uneven stress distribution on tabs and hinges.
Innovation Solution
A frame design with elastically deformable tongues featuring U-shaped grooves and clearance zones at the free ends of the grooves to distribute stress evenly, preventing plastic deformation and breakage by allowing controlled bending and insertion of movable shutters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tabs are made rigid to maintain structural strength, then the strength is improved, but the tabs cannot deform elastically to accommodate manufacturing tolerances, leading to assembly failures
Solution Approach 1:
The patent applies local quality by creating a U-shaped groove with specific geometric characteristics (radius R1 at the base, radius R2 at the free end where R2 > R1) in the tab. This localized geometric modification allows the tab to have different properties in different regions: the base remains strong and rigid while the free end becomes more compliant and capable of elastic deformation to accommodate manufacturing tolerances during assembly.
2Manufacturing precision
If the clearances between flaps and frame are reduced to improve manufacturing precision, then the manufacturing precision is improved, but the stress concentration increases, leading to tab breakage
Solution Approach 1:
The patent applies beforehand cushioning by designing the U-shaped groove with a larger radius R2 at the free end, which creates a stress-distributing geometry that cushions the impact of stress concentration during assembly. This pre-designed geometric feature compensates for the harmful effects of tight clearances by distributing stresses more evenly, preventing tab breakage even when manufacturing tolerances are tight.
3Stress or pressure
If the radius R1 at the base of the U-shaped groove is increased to reduce stress concentration, then the stress distribution is improved, but the structural integrity at the base is reduced
Solution Approach 1:
The patent uses local quality by specifying different radius values for different locations of the U-shaped groove: a smaller radius R1 at the base to maintain structural integrity, and a larger radius R2 at the free end to improve stress distribution and reduce concentration. This localized differentiation allows each region to optimize for its specific functional requirements.
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 frame design effectively distributes stress, reducing the risk of irreversible deformation and breakage of tabs, ensuring reliable operation and assembly of movable shutters.
Implementation Method 1
the frame comprising at least one bearing carried by an elastically deformable tongue... The movable tongue can thus be assimilated by flexion between a first position of the tongue, corresponding to its initial position before the assembly of the set of movable shutters and a deformed position in which the tongue allows passage for the insertion of the movable shutters
Data Source
Figure 1~2
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AI summary
The main subject matter of the present invention is a frame (2) for an air intake regulating device (1) of a vehicle, the frame (2) comprising at least two walls participating in defining at least one opening zone (4) for receiving a set of movable flaps (6) arranged parallel to one another, at least one movable flap (6) being capable of rotating about at least one pivot axis (P), the frame (2) further comprising at least one bearing (22) supported by an elastically deformable tab (24), the bearing (22) being configured to receive a pin participating in defining the pivot axis (P) of the movable flap (6), the tab (24) being delimited in a wall of the frame (2) by a U-shaped groove (28), the groove (28) comprising a base (30) and two arms (32) respectively extending an end of the base, each of the arms (32) having a free end (34) opposite the base (30), the frame (2) being characterised in that the groove (28) comprises at least one release zone (36) positioned at one of the free ends (34) of the branches (32) of said groove (28), said release zone (36) laterally extending the corresponding branch (32) while forming at least one protuberance.