Modular Active Grille Shutter Frame for Adjustable Width
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Solution Overview
Problem
Existing active grille shutter systems for vehicles are inefficient due to their one-piece molded frames, which require distortion during assembly, have low shipping density, and necessitate separate frames for different variants, leading to increased production and shipping costs.
Innovation Solution
A modular frame system with a primary frame piece and adjustable end caps connected via a sliding joint, allowing for adjustable widths and featuring rotatable vanes controlled by a motor housing to manage airflow, enabling easier assembly and increased shipping density through modular components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece molded frame is used for the active grille shutter system, then the structural integrity is improved, but the assembly complexity increases due to required distortion and the shipping density decreases due to empty space
Solution Approach 1:
The frame is divided into multiple separate molded parts instead of one complete molding. This segmentation allows each part to be manufactured independently without requiring distortion during assembly, while maintaining structural integrity through designed connection interfaces between segments.
2Strength
If a one-piece molded frame is used, then the structural integrity is improved, but the shipping density decreases due to mostly empty space
Solution Approach 1:
By dividing the frame into separate modular segments, the components can be stacked more closely together during shipping, eliminating the empty space problem associated with one-piece frames while maintaining structural integrity through the modular connection design.
3Ease of manufacture
If a one-piece molded frame is used, then the manufacturing process is simplified, but the adaptability decreases as a complete new frame must be molded for each variant
Solution Approach 1:
The frame is segmented into modular components that can be mixed and matched to create different variants. This allows a single set of base components to serve multiple applications, eliminating the need to mold completely new frames for each variant while maintaining manufacturing simplicity through standardized production of modular parts.
Solution Approach 2:
The modular frame components are designed with universal interfaces and standardized features that allow the same basic components to be used across multiple variants and applications. This multi-functionality enables a single component design to serve different purposes by combining with various optional elements.
4Ease of operation
If the frame is designed as multiple separate molded parts, then the assembly process is simplified and shipping density increases, but the device complexity increases due to multiple components
Solution Approach 1:
The frame is divided into a limited number of modular segments with standardized connection interfaces. This segmentation simplifies assembly by allowing components to be joined without distortion, while the modular design actually reduces overall complexity by enabling reuse of the same components across different configurations and variants.
Data Source
AI summary
An active grille shutter arrangement having a modular frame. The active grille shutter arrangement includes a primary frame piece defining a width and height of an aperture of the modular frame, wherein in the primary frame piece has a motor housing, and upper frame portion having a first end and a second end, a lower frame portion having a first end and a second end and the motor housing extends between the upper frame portion and the lower frame portion. There is a plurality of secondary frame pieces that are adjustably connected to the primary frame pieces, thereby allowing the width of the modular frame to be adjusted.