Modular Active Grille Shutter Frame for Scalable Vehicle Packaging
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Solution Overview
Problem
Current active grille shutter components require significant tooling investments and are often unique to one vehicle, leading to high development and program costs, as well as low shipping density due to their one-piece frame design, which is not scalable or versatile.
Innovation Solution
A modular active grille shutter arrangement with interchangeable primary and secondary frame pieces formed by extrusion and injection molding, allowing for various shapes and sizes without the need for new tooling, featuring a motor housing with vanes that can be rotated for airflow control and increased packaging density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece frame design is used for active grille shutters, then structural integrity is improved, but shipping density deteriorates and tooling costs increase
Solution Approach 1:
The frame is divided into multiple separate components including side rails, cross members, and mounting brackets that can be manufactured independently and assembled together. This segmentation allows each component to be optimized for its specific function while improving overall shipping density by reducing empty space in tooling and packaging.
2Strength
If a one-piece frame design is used for active grille shutters, then structural integrity is improved, but development cost deteriorates due to retooling requirements
Solution Approach 1:
The modular frame components are designed with standardized interfaces and universal mounting features that can accommodate different grille configurations and vehicle applications. This universality allows a single set of tooling to produce components for multiple programs, eliminating the need for expensive retooling when transitioning between different vehicle models or grille designs.
3Ease of operation
If a one-piece frame design is used for active grille shutters, then simplicity of assembly is improved, but versatility deteriorates as each application requires a new design
Solution Approach 1:
The frame is divided into modular components with standardized connection interfaces that allow different combinations of side rails, cross members, and mounting brackets to be assembled for various applications. This segmentation maintains assembly simplicity through standardized interfaces while providing design versatility by allowing customization of frame configurations for different vehicle models and grille requirements.
4Ease of manufacture
If traditional molding methods are used for active grille frames, then manufacturing capability is improved, but shipping density deteriorates due to empty space
Solution Approach 1:
The frame components are manufactured as separate molded parts that can be tightly packaged together, eliminating the empty space inherent in one-piece frame shipping. The segmented design allows components to be nested or stacked efficiently during shipping while maintaining the manufacturing capabilities of traditional molding processes for each individual component.
Data Source
AI summary
An active grille shutter arrangement having an assembled modular frame with a plurality of primary frame pieces formed by extrusion. Each one of the plurality of primary frame pieces has a first end, a second end and at least one key slot extending between the first end and the second end. Each of the plurality of frame pieces also includes a hollow bore extending through the each one of the plurality of primary frame pieces forming an aperture at the first end and an aperture at the second end. When the modular frame is assembled there is an upper frame portion and lower frame portion, both formed from one of the plurality of primary frame pieces. The arrangement also includes a number of alternate frame and vane pieces that allow several different active grille shapes and configurations to be formed.