Integral Hinge Air Duct Segments for Vehicle Front End
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Solution Overview
Problem
Existing vehicle front end designs with air duct devices are costly to produce and assemble, as they require coordinating and connecting multiple separate parts, which increases manufacturing and assembly expenses.
Innovation Solution
A vehicle front end element with an opening leading to an air duct device, where the air duct device is formed by two segments connected by an integral hinge, allowing for a one-piece molded part that can be easily assembled by swiveling and fixing the segments, reducing production and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are used to form the air duct device, then the device can be assembled from modular components, but the production costs and assembly costs increase due to coordination and connection requirements
Solution Approach 1:
The patent merges multiple separate air duct parts into a single integrated air duct device that is molded as one piece. This eliminates the need for coordinating and connecting multiple separate parts, thereby reducing both production costs and assembly costs while maintaining the functional requirements of the air duct system
2Adaptability or versatility
If multiple separate parts are used to form the air duct device, then the device can be assembled from modular components, but the assembly complexity increases due to coordination and connection requirements
Solution Approach 1:
The patent combines multiple air duct segments into a single molded part, eliminating the need for complex coordination and connection operations during assembly. The integrated design reduces assembly complexity while preserving the modular functionality needed for installation and maintenance
3Ease of manufacture
If a single integrated air duct device is used, then production costs and assembly costs are reduced, but the device may be difficult to manufacture as a one-piece molded part
Solution Approach 1:
The patent applies segmentation in the mold design rather than in the final product. The molding process is divided into multiple injection stages that form different sections of the air duct device sequentially, allowing complex geometries to be created as a one-piece part while maintaining manufacturing feasibility
4Ease of operation
If a single integrated air duct device is used, then assembly is simplified, but the manufacturing process becomes more challenging
Solution Approach 1:
The manufacturing process is segmented into multiple injection molding stages, where each stage forms a specific section of the air duct device. This allows the complex one-piece part to be manufactured systematically while maintaining assembly simplicity in the final product
Data Source
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AI summary
The invention relates to a vehicle front end (50) with at least one vehicle front end element (10) with at least one opening (16) leading to an air duct device (18) being positioned downstream said opening (16) and to a method of manufacturing an air duct device (18) for such a vehicle front end element (10). The object of the invention is to provide a vehicle front end element (10) with an opening (16) leading to an air duct device (18) and a method of producing an air duct device (18) for a vehicle front end element (10) causing low production costs and but keeping the assembly costs low. A vehicle front end element (10) according to the invention comprises at least one opening (16) leading to an air duct device (18) being positioned downstream said opening (16), wherein the air duct device (18) provides a surrounding channel (22) and wherein the air duct device (18) is formed by at least two segments (24, 26) being connected by an integral hinge (28).