Deformable Active Grille with Pivoting Segments for Impact Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Active aerodynamic systems in motor vehicles, such as grille with active shutters, are prone to malfunctioning or non-functioning due to shocks, which can lead to serious consequences like engine cooling system failure, especially during low-speed crashes, where the system's robustness is compromised by its positioning near the front bumper.
Innovation Solution
A grille with active shutters featuring a support structure composed of multiple parts that can pivot relative to each other, allowing for shock absorption without affecting the system's operation, with movable elements connected to an actuator via a connection providing multiple degrees of freedom, such as a ball-and-socket type connection, enabling the structure to deform and reorient without damaging the mobile elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the active louvered grille is positioned close to the front bumper to improve aerodynamic performance, then aerodynamic efficiency is improved, but the system becomes vulnerable to impacts and shocks
Solution Approach 1:
The support structure is divided into multiple parts (first part, second part, third part) that can pivot relative to each other. This segmentation allows the structure to absorb impacts through controlled movement of individual segments rather than rigid failure, resolving the contradiction between positioning for aerodynamic performance and protecting against impact damage.
Solution Approach 2:
The support structure transitions from a static rigid configuration to a dynamic articulated system with pivot joints. The movable parts can adapt their configuration in response to impacts, allowing the system to maintain functionality under variable conditions including shock loads, thus improving reliability while accommodating impact exposure.
2Manufacturing precision
If the movable elements are rigidly connected to the actuator to ensure precise control, then control precision is improved, but the system becomes susceptible to damage from shocks and impacts
Solution Approach 1:
A link mechanism serves as an intermediary between the actuator and the movable element. This intermediate component provides the necessary degrees of freedom to accommodate shocks and impacts while still transmitting the actuator's control movements to the movable element, thus maintaining control precision without sacrificing impact resistance.
Solution Approach 2:
The connection between the actuator and movable element is designed with variable degrees of freedom. The link allows rotational movement in certain directions to absorb impacts while maintaining controlled movement in other directions for precise positioning, effectively changing the mechanical parameters of the connection based on operational needs.
3Ease of manufacture
If the support structure is designed as a single rigid piece to simplify manufacturing, then manufacturing complexity is reduced, but the system cannot absorb shocks without malfunctioning
Solution Approach 1:
The support structure is segmented into multiple manufacturable parts that can be produced using standard injection molding tools. This segmentation enables shock absorption through controlled pivoting while keeping each individual part within the manufacturing capabilities of conventional equipment, thus resolving the contradiction between manufacturing simplicity and shock absorption.
Solution Approach 2:
The support structure parts are made from composite materials (polypropylene with glass fibers or polyamides with glass fibers) that combine the benefits of plastic manufacturing ease with enhanced mechanical strength and impact resistance, allowing complex articulated designs to be manufactured with relative simplicity while maintaining reliability under shock loads.
4Reliability
If the entire active shutter grille must be replaced after impact to ensure functionality, then system reliability is maintained, but repair costs and time increase
Solution Approach 1:
The modular segmented design of the support structure allows individual parts to be replaced if damaged, rather than requiring replacement of the entire grille assembly. This segmentation directly improves ease of repair while maintaining system reliability, as only the affected segment needs to be serviced.
Solution Approach 2:
The design enables selective replacement of only the damaged component(s) while preserving functional parts of the system. This partial replacement approach reduces waste and repair costs while ensuring the repaired system maintains full functionality, effectively applying the discarding and recovering principle to improve ease of repair.
Data Source
Figure 1~2
AI summary
The invention relates to an active flap grille (2) of a motor vehicle, characterized in that it comprises: - movable elements (6), and – a support structure (4) receiving the movable elements (6), the support structure (4) comprising multiple interconnected parts (8, 10) each receiving a set of movable elements (6), the parts (8, 10) being able to pivot with respect to one another, the active flap grille (2) comprising at least one actuator (14) that is able to move the movable elements (6) and is connected to at least one movable element (6), the movable element (6) connected to the actuator (14) is connected to the actuator (14) via the intermediary of a connection (16) which is able to impart to it at least one degree of freedom with respect to the actuator (14).