Foam Air Guide and Cooler Seal Layout for Vibration Decoupling
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Solution Overview
Problem
Existing air guiding systems in motor vehicles fail to effectively direct airflow to cooler elements while minimizing vibration transmission and noise generation, particularly in electric vehicles where range optimization and vibration decoupling are critical.
Innovation Solution
An air guiding element made of expanded polypropylene foam (EPP foam) is integrated with a cooler element, featuring an elastic seal that tensions to the rear and a force-fit second seal, providing secure sealing and vibration decoupling, and includes a sound generator with a funnel-shaped opening to direct sound efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid air guiding systems are used, then structural strength is improved, but vibration transmission and noise generation increase
Solution Approach 1:
The patent employs foam material with porous structure to manufacture the air guiding system. The porous foam structure absorbs vibrations and reduces noise transmission while maintaining sufficient structural strength for air guidance functionality, directly resolving the contradiction between strength and vibration/noise generation.
Solution Approach 2:
The patent uses composite foam material that combines structural integrity with vibration-damping properties. The foam composite provides both the mechanical strength needed for structural support and the inherent vibration isolation characteristics that reduce noise transmission to surrounding components.
2Weight of moving object
If foam material with low density is used, then weight is reduced for range optimization, but sealing effectiveness deteriorates
Solution Approach 1:
The patent optimizes the foam material density parameter to a specific range that balances weight reduction with sealing effectiveness. By carefully controlling the foam density and compression characteristics, the system achieves lightweight construction while maintaining sufficient contact pressure for effective sealing against the cooler element.
Solution Approach 2:
The foam material's dynamic compression characteristics enable it to adapt to manufacturing tolerances and assembly variations. The foam can be compressed during assembly to create reliable seals, then maintains adequate contact pressure under operating conditions, providing both weight reduction and sealing reliability.
3Device complexity
If the air guiding element is made as an integral component, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent integrates multiple functions (air guidance, sealing, vibration isolation) into a single integral foam component. This merging of functions reduces the total number of parts and assembly steps while the foam material's inherent compliance compensates for moderate manufacturing tolerances, making integral construction feasible.
Solution Approach 2:
The foam material's porous structure allows for easier molding of complex integral geometries compared to rigid materials. The foam can be injected into intricate molds and maintains dimensional stability, enabling the production of integrated components with acceptable precision for sealing and guidance functions.
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
The solution ensures efficient airflow to cooler elements, reduces vibration and noise transmission, and optimizes range in electric vehicles by using lightweight foam and effective sealing, while also directing sound emissions to enhance visibility.
Implementation Method 1
The cooler element has an elastic seal having a first sealing section at least in an outer partial section
Implementation Method 2
Air guiding elements made of foam have a low component weight and are therefore particularly well suited for use in electric vehicles
Data Source
AI summary
The invention relates to an arrangement of an air guiding element (12) made of foam on a cooler element (14) in a front end (16) of a motor vehicle (10), wherein the air guiding element (12) extends up to the cooler element (14) when viewed in the longitudinal direction of the vehicle, and the cooler element (14) has at least in an outer partial section an elastic seal (52) having a first sealing section (54), wherein the air guiding element (12) bears against the first sealing section (54) in such a manner that the first sealing section (54) is brought into a tensioned position to the rear by the air guiding element (12) when viewed in the longitudinal direction of the vehicle. The invention further relates to a cooler element (14) for arrangement in a front end (16) of a motor vehicle (10) and to an air guiding element (12) made of foam.