Unitary Carrier Air Guard for EV Front End Module Weight Reduction
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Solution Overview
Problem
The design of front end modules for electric vehicles is hindered by the need to reduce weight and cost while maintaining adequate cooling performance, which is lower than that required for internal combustion engine vehicles, and existing solutions complicate the structure due to the presence of a lower carrier member that interferes with other components.
Innovation Solution
A front end module configuration for electric vehicles that includes a carrier with a receiving opening for a heat exchanger, an active air flap below the carrier, and an air guard above the flap, forming a unitary one-piece structure to simplify assembly, reduce weight, and enhance cooling performance by managing airflow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the lower member of the carrier is eliminated to reduce weight and cost, then weight and manufacturing cost are reduced, but the structural strength and support function may be compromised
Solution Approach 1:
The air guard is integrated with the carrier to form a unitary one-piece structure, combining two previously separate components into one. This merging maintains structural strength while reducing the total number of parts, eliminating the need for the lower member, and reducing both weight and manufacturing complexity.
Solution Approach 2:
The carrier is designed with a specific geometric structure including a cross portion and a pair of vertical portions that extend vertically from both ends of the cross portion. This segmentation creates a structurally efficient design that provides necessary support strength while minimizing material usage and weight.
2Ease of manufacture
If the carrier structure is simplified by eliminating the lower member, then manufacturing cost is reduced, but the assembly complexity with other components may increase
Solution Approach 1:
By integrating the air guard with the carrier into a unitary structure, the patent reduces the total number of separate components that need to be assembled. This merging simplifies the assembly process with other components while maintaining all necessary functions, directly addressing the ease of manufacture improvement.
3Reliability
If the active air flap is positioned below the carrier to accommodate the lower grille, then cooling performance is improved, but the lower member interferes with other components
Solution Approach 1:
The lower member is extracted or removed from the carrier structure entirely. This elimination removes the source of interference with other components while the air guard is positioned to cover the heat exchanger, maintaining adequate cooling performance without the conflicting lower member.
4Ease of operation
If the carrier and air guard are integrated as a unitary structure, then assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The air guard and carrier are merged into a unitary one-piece structure that can be manufactured as a single molded part. This integration simplifies assembly operations significantly, and while it does require molding precision, the design accommodates typical manufacturing tolerances through its geometric features and sealing rib configurations.
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 configuration reduces manufacturing costs and weight by eliminating the lower carrier member, improves heat exchange performance through optimized airflow management, and simplifies assembly by integrating the carrier and air guard as a single unitary structure.
Implementation Method 1
an active air flap adjacent to the lower grille to allow outside air to be guided to a heat exchanger by opening the active air flap
Implementation Method 2
a heat exchanger disposed within the receiving opening
Data Source
AI summary
A front end module for an electric vehicle is provided. The front end module includes a carrier that is disposed inside a bumper cover having a lower grille. The carrier includes a receiving opening within which a heat exchanger is disposed. In addition, an active air flap is disposed below the carrier and adjacent to the lower grille, the active air flap having a plurality of pivotable flaps. Further, the front end module includes an air guard that is disposed above the active air flap and covers a front surface of the heat exchanger disposed within the receiving opening of the carrier.