Modular Active Grille Shutter Frame Assembly
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Solution Overview
Problem
Existing active grille systems for vehicles have inefficiencies in assembly and shipping due to being molded as complete parts, requiring distortion during assembly and having low shipping density, which hinders quick engine warm-up and fuel efficiency during start-up.
Innovation Solution
A modular frame system comprising a primary frame piece and secondary frame pieces that connect via interlocking joints and bars, allowing for assembly without distortion and increased shipping density by using multiple separate molded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complete one-piece frame is molded for the active grille shutter system, then the structural integrity is maintained, but the assembly requires distortion of frames or vanes and has low shipping density
Solution Approach 1:
The frame is divided into multiple separate molded parts including a first frame portion, a second frame portion, and a cross member that can be assembled together. This segmentation eliminates the need for distortion during assembly while maintaining structural integrity through proper connection design between the modular components.
2Strength
If a complete one-piece frame is molded, then structural integrity is maintained, but shipping density is low due to empty space
Solution Approach 1:
By dividing the frame into separate modular components (first frame portion, second frame portion, cross member), the parts can be packaged more efficiently in shipping containers, reducing empty space and increasing shipping density while maintaining the structural integrity of the assembled frame.
3Ease of manufacture
If a one-piece frame is used, then manufacturing is simpler, but variants requiring additional vanes or base air flow require complete new frame molding
Solution Approach 1:
The frame is segmented into modular portions that can be selectively combined. The first frame portion, second frame portion, and cross member can be assembled in different configurations to accommodate various vane arrangements and air flow requirements, providing configuration flexibility without requiring complete new frame molds.
Solution Approach 2:
The modular frame components are designed with universal connection features that allow the same basic parts to serve multiple configuration needs. The cross member and frame portions can be adapted to support different vane configurations and air flow patterns, making the system multi-functional across different application variants.
4Ease of manufacture
If distortion is applied to assemble the complete system onto the one piece frame, then assembly is possible, but manufacturing precision is compromised
Solution Approach 1:
By segmenting the frame into multiple parts designed to fit together, the invention eliminates the need for distortion during assembly. Each component can be manufactured to precise specifications and assembled without compromising manufacturing precision or frame alignment accuracy.
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. The modular frame of the active grille shutter arrangement is formed by the connection of the primary frame piece in the secondary frame piece, wherein the modular frame defines the aperture. The active grille shutter arrangement further includes a plurality of vanes rotatably positioned between the first end cap and the second end cap for controlling the amount of air flowing through the one or more apertures of the modular frame. The motor housing of the frame piece extends between the upper frame portion and the lower frame portion.