Active Grille Shutter Vanes With Soft Flaps for Sealing and Noise Control
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Solution Overview
Problem
Current active grille shutter designs suffer from air leakage around the perimeter of the vanes and rattling noise due to clearance between the vanes and the frame.
Innovation Solution
Incorporation of soft flaps molded into the vanes and a stepped wall on the frame to create interference for improved sealing and reduce rattling, with the flaps deflecting gradually during closure to minimize torque load on the actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance is provided between the vanes and frame to prevent binding, then ease of operation is improved, but sealing capability deteriorates and rattling noise increases
Solution Approach 1:
The patent uses flexible sealing flaps made of elastomeric material that can deflect and conform to the frame surface. These flaps are attached to the vanes and extend toward the frame, making contact when the vane is in the closed position to seal the gap, while allowing clearance to exist when the vane is open for smooth operation.
2Ease of operation
If clearance is provided between the vanes and frame to prevent binding, then ease of operation is improved, but harmful factors (rattling noise) increase
Solution Approach 1:
The flexible sealing flaps not only provide sealing but also act as dampers to reduce rattling noise. The elastomeric material absorbs vibrations and prevents the hard contact noise that would occur with rigid components, while still allowing the necessary clearance for smooth operation.
3Reliability
If sealing flaps are added to improve sealing, then sealing capability is improved, but device complexity increases
Solution Approach 1:
The sealing flaps are integrated with the vane structure rather than being separate components. The flaps are molded or attached directly to the vane body, combining the sealing function with the existing vane structure and reducing the number of separate parts that would need to be manufactured and assembled.
Solution Approach 2:
The sealing flaps serve multiple functions: they provide sealing against the frame, act as noise dampers to reduce rattling, and can help center the vane in the frame opening. This multi-functionality reduces the need for additional separate components.
4Reliability
If interference is created by stepped wall to improve sealing, then sealing capability is improved, but actuator torque requirement increases
Solution Approach 1:
The flexible sealing flaps gradually deflect as the vane moves from open to closed position, distributing the sealing force over a range of motion rather than requiring sudden high force at the end position. This reduces the peak torque requirement on the actuator.
Solution Approach 2:
The stepped wall feature creates a progressive interference that begins to deflect the sealing flaps before the vane reaches the fully closed position. This gradual deflection acts as a cushion, preventing sudden high-force contact and reducing the actuator torque spike that would occur with abrupt sealing.
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
Enhances sealing capability and reduces or eliminates rattling noise by ensuring a tight fit between the vanes and frame, maintaining centered vanes and reducing actuator stress.
Implementation Method 1
the flaps to be deflected in a gradual manner, so the actuator motor is not taxed with a sudden increase in required torque
Data Source
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AI summary
Typical active grille shutter vanes meet the frame at either end, with a small clearance between the parts, to avoid the parts binding together. This invention adds a set of soft flaps, which are molded in a two-shot process, to allow the vanes to seal against the frame while closed but sit free of the frame while open. This clearance is accomplished by adding a stepped wall to the frame component, to create an interference between the vane flaps while turning to the closed position, causing the flaps to be deflected in a gradual manner, so the actuator motor is not taxed with a sudden increase in required torque.