Extruded Hollow Profile Flap for Vehicle Air Intake Sealing
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Solution Overview
Problem
The existing manufacturing process for motor vehicle shutter devices by molding lacks flexibility and is costly to modify, as changing types or dimensions requires complete mold changes, limiting the ability to optimize air intake efficiency and aerodynamics.
Innovation Solution
A method involving extrusion of a hollow profile with thinner outer skins, allowing for adjustable length and structure modifications without changing molds, combined with coextrusion for added seals and spacers, enabling lighter and more rigid shutters with improved aerodynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding process is used to manufacture flaps, then structural integrity is ensured, but manufacturing flexibility is reduced and costs increase due to complete mold changes
Solution Approach 1:
The flap is divided into two main components: a hollow profile body produced by extrusion and end caps produced by molding. This segmentation allows the main body to be manufactured with high flexibility through extrusion while only the end caps require molding, significantly reducing the complexity of mold changes when flap specifications need to be modified.
Solution Approach 2:
The end caps are designed to fit onto the extruded hollow profile body, merging two different manufacturing processes (extrusion and molding) into a single integrated component. This combination leverages the flexibility of extrusion for the main body while using molding only for the end caps, optimizing both manufacturing flexibility and structural integrity.
2Weight of moving object
If molding process is used to manufacture flaps, then complete flaps are produced, but weight increases due to thicker material required for molding
Solution Approach 1:
The hollow profile body is manufactured using extrusion, which enables the production of thin-walled structures with consistent wall thickness. This approach allows the use of thinner materials compared to molding, significantly reducing the weight of the flap while maintaining structural integrity through the hollow profile design.
3Strength
If extrusion is used to produce hollow profile, then thinner outer skins are achieved, but structural rigidity may be compromised
Solution Approach 1:
The hollow profile body is reinforced with internal spacers that divide the hollow space into multiple compartments. This segmentation increases the moment of inertia of the cross-section, significantly improving structural rigidity and resistance to bending without increasing the wall thickness or overall weight of the extruded profile.
Solution Approach 2:
The end caps are designed to fit tightly onto the extruded hollow profile body, creating a composite structure that combines the lightweight properties of the thin-walled extrusion with the structural support provided by the capped ends. This composite approach enhances overall rigidity while maintaining low weight.
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 approach results in lighter, more rigid, and cost-effective shutters with enhanced aerodynamic performance and manufacturing flexibility, as the extrusion process allows for thinner skins and easier modifications to length and structure without the need for expensive mold changes.
Implementation Method 1
extrusion of a hollow profile formed of an outer skin made of a first material
Implementation Method 2
the extrusion step is a coextrusion between the first material intended to form the hollow profile and a second material intended to form a sealing joint on at least one of the edges of the hollow profile
Data Source
Figure 1~2
Figure 3~5
Figure 3
AI summary
The present invention concerns a method for producing a flap (3) for a sealing device (1) of a motor vehicle, said method comprising the following steps: extruding a hollow profile section formed from an outer skin (310) made from a first material, cutting the hollow profile section to a predefined length (L) so as to form a flap body (31), fitting end pieces (30) at the ends of the flap body (31). The invention also concerns a flap of a device for sealing a front end air intake obtained by such a method.