Integrated Engine Louver Carrier for Airflow and Warm-Up Control
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Solution Overview
Problem
Current automobile cooling systems are inefficient, particularly at start-up, as they do not quickly bring the engine to optimal operating temperature, leading to reduced fuel efficiency and aerodynamic inefficiencies due to separate components that increase manufacturing complexity and costs.
Innovation Solution
An integrated active ducting system for automobiles, featuring a carrier with apertures and rotatable louvers actuated by an integrated mechanism, allowing for controlled airflow through coextruded louvers with slip coats for reduced friction and wear resistance, which can be manufactured as a single unit to reduce parts and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate cooling components are used to control airflow around the engine, then airflow control capability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple separate cooling components (carrier, ducting, louvers, actuators) into a single integrated assembly. The carrier serves as both a structural support and a housing for the ducting system, while the ducting is molded as one piece with the carrier. This merging eliminates the need for multiple separate parts and simplifies the overall cooling system architecture.
Solution Approach 2:
The integrated carrier-ducting assembly performs multiple functions simultaneously: it provides structural support for the radiator and condenser, serves as a airflow distribution system through integrated ducting, and incorporates adjustable louvers for directional control. This multi-functionality reduces the need for additional separate components.
2Ease of manufacture
If separate cooling components are manufactured and assembled, then manufacturing flexibility is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The carrier and ducting are molded as a single integrated component using injection molding technology. This eliminates the need for separate manufacturing and assembly operations for these parts, reducing both manufacturing complexity and assembly time while maintaining manufacturing flexibility through mold design variations.
3Temperature
If traditional cooling systems operate continuously, then cooling capability is improved, but fuel efficiency deteriorates during engine start-up
Solution Approach 1:
The system uses adjustable louvers that can dynamically change their position to control airflow direction and volume. During engine start-up, the louvers can be positioned to minimize airflow and heat removal, preserving heat for faster warm-up. Once the engine reaches optimal temperature, the louvers adjust to provide adequate cooling, optimizing fuel efficiency across different operating conditions.
Solution Approach 2:
The system incorporates temperature sensors that monitor engine and coolant temperatures, providing feedback to the control system. This feedback enables the actuators to adjust louver positions based on real-time temperature conditions, ensuring the engine reaches optimal temperature quickly while maintaining efficient cooling operation.
4Ease of manufacture
If vehicle components cause poor airflow, then manufacturing simplicity is improved, but aerodynamic efficiency deteriorates
Solution Approach 1:
The integrated ducting features smooth curved transitions and aerodynamically optimized shapes that guide airflow efficiently around the radiator and condenser. The curved ducting design reduces turbulence and airflow resistance compared to sharp-edged or angular designs, improving aerodynamic efficiency while maintaining manufacturing simplicity through injection molding.
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
This solution enhances airflow control, improves fuel efficiency by quickly reaching optimal engine temperature, reduces manufacturing complexity, and minimizes aerodynamic inefficiencies by integrating cooling components into existing vehicle parts.
Implementation Method 1
Each seal includes a slip coat for reducing the friction between the seals
Implementation Method 2
The actuator is operable for moving the louver between an open position and a closed position
Implementation Method 3
when the louver is in the open position, air flow passes through the aperture
Data Source
AI summary
A carrier for an automobile with integrated active ducting, and a method of making a louver therefor. The carrier includes at least one aperture, and at least one louver rotatably mounted in the aperture. Also attached to the carrier is an actuator, and the actuator is connected to the louver. The actuator is operable for moving the louver between an open position and a closed position such that when the louver is in the open position, air flow passes through the aperture.