Active Grille Shutter Vane Sealing to Prevent Air Leakage and Rattle
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Solution Overview
Problem
Current active grille shutter designs fail to provide full blockage against air flow due to air leakage around the perimeter of the vanes and tend to rattle against the frame due to clearance requirements.
Innovation Solution
The addition of soft flaps molded in a two-shot process to the vanes, which seal against the frame when closed and sit free when open, along with a stepped wall on the frame component to increase interference and reduce rattling, while providing centering functionality to prevent unwanted noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance is provided between vanes and frame to prevent binding, then ease of operation is improved, but sealing capability deteriorates due to air leakage around the perimeter
Solution Approach 1:
A flexible seal flap is attached to the vane, extending toward the frame. When the vane rotates to the closed position, the seal flap contacts the frame to prevent air leakage. The flexibility of the seal flap allows it to conform to the frame surface while maintaining sealing effectiveness.
Solution Approach 2:
A stepped wall structure is provided on the frame with different height levels. The first step provides a surface for the seal flap to contact at a first height, while a second step at a lower height provides additional sealing support. This multi-level parameter change enhances sealing capability without requiring complete elimination of clearance.
2Ease of operation
If clearance is provided between vanes and frame, then ease of operation is improved, but harmful factors increase due to rattling noise
Solution Approach 1:
The flexible seal flap not only provides sealing but also acts as a damping element that reduces rattling noise. When the vane is in the closed position, the seal flap contacts the frame and the flexible material absorbs vibrations, preventing rattling noise while allowing minimal clearance to be maintained.
Solution Approach 2:
The stepped wall structure provides a cushioning effect by creating a gradual transition zone. The first step at a higher height provides initial contact and cushioning, while the second step at a lower height provides additional support, preventing direct hard contact between the vane and frame that would cause rattling.
3Reliability
If seal flaps are added to improve sealing, then sealing capability is improved, but device complexity increases
Solution Approach 1:
The seal flap is integrated with the vane as a single assembly, and the stepped wall structure is incorporated into the frame as a unified feature. This merging of components reduces the number of separate parts and simplifies assembly while maintaining improved sealing capability.
Solution Approach 2:
The seal flap is constructed from a flexible material that can be molded or formed as a simple thin element. This approach adds minimal structural complexity while effectively preventing air leakage. The flexibility of the material allows it to conform to the frame surface without requiring complex mechanical structures.
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 sealing capability and reduces or eliminates rattling noise by ensuring minimal space around the vane ends when closed and maintaining the vanes centered, thus reducing the torque load on the actuator motor.
Implementation Method 1
a set of soft flaps, which are molded in a two-shot process, to allow the vanes to seal against the frame while closed
Implementation Method 2
adding a stepped wall to the frame component, to create or increase an interference between the vane flaps while turning to the closed position, causing the flaps to be deflected in a gradual manner
Data Source
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.