Modular Active Grille Frame Assembly
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Solution Overview
Problem
Existing active grille systems for vehicle cooling have inefficiencies in assembly, shipping density, and adaptability due to being molded as complete parts, which require distortion during assembly and result in low shipping density and limited variant accommodation.
Innovation Solution
A modular frame system comprising interchangeable upper and lower frame portions with end caps and interlocking joints, allowing for assembly without distortion and increased shipping density through modular design, with rotatable vanes for airflow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the frame is molded as a complete one-piece part, then the structural integrity is maintained, but the assembly requires distortion of frames or vanes and the shipping density is low
Solution Approach 1:
The frame is divided into multiple separate molded parts (upper frame portion, lower frame portion, end caps, center bar) that can be manufactured independently without distortion and then assembled together using interlocking joints, eliminating the need to distort frames or vanes during assembly
2Stability of the object's composition
If the frame is molded as a complete one-piece part, then the structural integrity is maintained, but the shipping density is low due to mostly empty space
Solution Approach 1:
The frame is segmented into multiple separate molded parts that can be stacked more closely together during shipping, significantly increasing shipping density while maintaining structural integrity through precise interlocking joints with features such as bar end joints sliding into bar end cap joints and snap-fit connections
3Ease of manufacture
If the frame is molded as a complete one-piece part, then the manufacturing process is simplified, but adaptability to various variants is limited
Solution Approach 1:
The frame is divided into modular segments (upper frame portion, lower frame portion, end caps, center bar) that can be selectively combined to create different configurations for various vehicle applications, allowing adaptability to different variants without requiring complete new tooling
Solution Approach 2:
The modular frame components are designed with standardized interlocking joints and interfaces that can be used across different vehicle applications and variants, allowing the same basic components to serve multiple functions and configurations
Data Source
AI summary
An active grille shutter arrangement having an assembled modular frame. The assembled modular frame includes an upper frame portion and a lower frame portion each having a first end and a second end. A first end cap is connectable to both the first end of the upper frame portion and the first end of the lower frame portion. The connection between the first end of the upper frame portion and the first end of the lower frame portion includes an upper bar end joint formed on the front end of the upper frame portion and a lower bar end joint formed on the first end of the lower frame portion. The upper bar end joint slides into an upper bar end cap joint formed on the first end cap and the lower bar end joint slides into a lower end cap joint formed on the first end cap.