Bumper Step Pad Gap Seal Aerodynamic Drag Reduction
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Solution Overview
Problem
Conventional front bumper designs with grille shutter systems experience airflow leaks through the design gap between the bumper and radiator grille, leading to increased aerodynamic drag and decreased fuel economy, even when the grille shutter is in a closed configuration.
Innovation Solution
A front bumper step with a gap seal is introduced to prevent airflow through the gap between the bumper fascia and the grille assembly, which can be a separate element or integrated with the step pad, and is optionally fabricated from flexible materials to effectively seal the airflow leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a design gap of 15 mm to 21 mm is provided between the bumper and radiator grille, then ease of manufacture and assembly is improved, but aerodynamic drag increases due to airflow leakage
Solution Approach 1:
The bumper assembly is segmented into distinct components: the bumper fascia, the grille assembly, and a separate gap seal element. This segmentation allows the gap seal to be independently positioned and adjusted to prevent airflow leakage while maintaining the design gap for manufacturing ease.
Solution Approach 2:
A gap seal element is introduced as an intermediary component between the bumper fascia and the grille assembly. This intermediary element blocks airflow through the design gap while allowing both components to maintain their original positions and manufacturing tolerances.
2Loss of energy
If the grille shutter system is closed to reduce aerodynamic drag, then fuel economy is improved, but airflow leakage through the design gap increases drag
Solution Approach 1:
The airflow leakage problem is extracted from the main grille shutter system by introducing a separate gap seal element. This allows the grille shutter to focus on controlling major airflow while the gap seal addresses the specific issue of leakage through the design gap.
Solution Approach 2:
The design gap, which originally causes harmful airflow leakage, is converted into a beneficial feature by using it as the installation location for the gap seal. The gap that would otherwise be a source of drag becomes the strategic position for preventing leakage.
3Force
If a gap seal is added to prevent airflow leakage, then aerodynamic drag is reduced, but device complexity increases
Solution Approach 1:
The gap seal element is designed as a flexible, thin sealing component that can be easily manufactured and installed. This flexible film approach prevents airflow leakage without requiring complex rigid structures or multiple components.
Solution Approach 2:
The gap seal is designed to integrate with the existing bumper or grille assembly through various attachment methods (adhesive, mechanical retention, or snap-fit). This merging approach incorporates the sealing function into the existing structure rather than adding a completely separate system.
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 gap seal significantly reduces aerodynamic drag and improves fuel economy by preventing airflow leakage, as demonstrated by wind tunnel testing, even when the grille shutter is in a closed position.
Implementation Method 1
aerodynamic drag of the vehicle, lessening fuel economy
Data Source
AI summary
A front bumper step for a vehicle includes a step portion and a gap seal configured to prevent a flow of air through a gap defined between a front bumper fascia of the vehicle and a front grille assembly of the vehicle. The gap seal may be provided as an integral unit with a step pad portion of the front bumper step portion. The vehicle may include an active grille shutter system, and the front grille assembly may be an upper grille assembly. The gap seal may be fabricated of a flexible material.