Front-End Cooling Shutter With Roller Blind Headwind Support
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Solution Overview
Problem
Existing cooling devices for motor vehicles face challenges in withstanding dynamic pressure at high driving speeds and preventing damage from strong headwinds, while also optimizing airflow and reducing drag coefficient.
Innovation Solution
A cooling device featuring a roller blind as the closing element with a grid supporting structure that includes intersecting struts and plate-shaped support elements, ensuring a secure and flow-optimized seal, and a support frame made of plastic with integrated metal struts for enhanced sturdiness and weight savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closing element is used to seal the through-flow opening, then sealing performance against headwinds is improved, but the closing element may be damaged by strong dynamic pressure at high driving speeds
Solution Approach 1:
The grid supporting structure acts as an intermediary element between the roller blind and the external environment. It provides mechanical support to the roller blind, distributing the dynamic pressure across multiple struts and preventing the blind from being pushed through the opening or damaged, while allowing the roller blind to maintain its sealing function.
Solution Approach 2:
The roller blind is designed as a flexible sealing element that can conform to the opening geometry and maintain contact for sealing. Its flexibility allows it to adapt to pressure variations while the rigid grid structure provides the necessary strength to withstand high dynamic pressures.
2Strength
If a rigid support structure is used to protect against headwinds, then structural strength is improved, but weight increases
Solution Approach 1:
The support structure is segmented into a grid of intersecting struts rather than using a single solid panel. This segmentation provides sufficient structural strength to resist headwinds while reducing material usage and weight compared to a solid rigid structure. The grid pattern distributes forces efficiently across multiple elements.
Solution Approach 2:
The support frame combines plastic material for the main structure with integrated metal struts for enhanced strength. This composite approach provides the necessary rigidity to withstand high dynamic pressures while keeping the overall weight lower than a fully metal construction would require.
3Loss of energy
If the through-flow opening is completely closed, then drag coefficient is reduced, but airflow to the heat exchanger is blocked
Solution Approach 1:
The roller blind is designed as a movable closing element that can dynamically adjust between completely closed and completely open positions. This dynamic capability allows the system to optimize for drag reduction when cooling is not needed, and switch to full airflow when heat exchanger cooling is required, rather than being fixed in one state.
Data Source
AI summary
A cooling device for a front end of a motor vehicle has a heat exchanger which has a large number of coolant channels around which air can flow, and an apparatus which is connected upstream of the heat exchanger and has a support frame having a through-flow opening for air to flow to the heat exchanger, and at least one closing element that is movably mounted on the support frame and is intended to open, partially open, and close the through-flow opening. The closing element is designed as a pull-down shade which extends so as to close the through-flow opening in a first end position over the support frame and completely opens the through-flow opening in a second, rolled-up end position, and the support frame has a lattice supporting structure which is located in the through-flow opening and comprises intersecting struts.