Modular Airflow Shutter Cassette for Variable Cooling Module Lengths
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Solution Overview
Problem
Existing motor vehicle air flow control systems require multiple shutter types with different dimensions, leading to increased development and manufacturing costs due to complex architectures and variations in size, particularly in length.
Innovation Solution
A cassette with modular shutters that can be assembled in a reversible and integral manner, allowing for adjustable length and direction of extension, using complementary coupling members and transmission members to transmit movement between adjacent shutters, facilitating a simple and cost-effective assembly adaptable to various cooling modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple shutter types with different dimensions are used to accommodate complex architectures and size variations, then the adaptability to different cooling modules is improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The shutter is divided into multiple modular elements that can be coupled together in series along a longitudinal axis. Each element has standardized coupling members (first coupling member at one end, second coupling member at the other end) that enable interchangeable assembly. This segmentation allows the shutter to be configured in different lengths and arrangements to suit various cooling module architectures without requiring entirely different shutter types.
Solution Approach 2:
The coupling members are designed with universal compatibility - the first coupling member of one element can connect to the second coupling member of another element, creating a standardized interface system. This universal coupling mechanism allows the same basic shutter element design to serve multiple functions and configurations across different vehicle models and cooling module designs, reducing the need for multiple specialized shutter types.
2Adaptability or versatility
If multiple shutter types with different dimensions are used to accommodate size variations, then the adaptability to different cooling modules is improved, but the manufacturing costs increase
Solution Approach 1:
By segmenting the shutter into standardized modular elements with uniform coupling mechanisms, the manufacturing process can produce identical or near-identical components in large volumes, achieving economies of scale. The standardized coupling members (with features like cylindrical shapes, hollow cylindrical receptacles, and stop means) can be manufactured using the same tooling and processes for all elements, significantly reducing per-unit manufacturing costs compared to producing multiple different shutter types.
Solution Approach 2:
The universal coupling member design allows a single shutter element type to be used across multiple applications and configurations. This universality enables manufacturers to produce a limited range of standardized elements that can be assembled into various shutter configurations, thereby reducing tooling costs, inventory requirements, and manufacturing complexity while maintaining the ability to adapt to different cooling module sizes and architectures.
3Ease of manufacture
If a modular assembly of shutters is used to reduce the number of shutter types, then the manufacturing costs are reduced, but the ease of assembly may be affected
Solution Approach 1:
The segmented modular design with standardized coupling members actually improves ease of assembly compared to single-piece shutters. The coupling members are designed with intuitive features such as cylindrical shapes that fit into hollow cylindrical receptacles, stop means that guide proper alignment, and complementary geometries that naturally orient the elements during assembly. This modular approach allows assembly workers to simply connect elements in sequence without requiring complex alignment procedures or specialized tools.
Solution Approach 2:
The coupling members are pre-configured with alignment features and geometric constraints that automatically guide the assembly process. The stop means and cylindrical geometries are designed to preliminarily position the elements correctly before final engagement, eliminating the need for complex alignment operations during assembly. This preliminary configuration of the coupling interfaces ensures that even workers with minimal training can assemble the modular shutters quickly and correctly.
Data Source
AI summary
A cassette is for a device that controls the circulation of an air flow of a vehicle. The cassette includes a frame and a plurality of mobile shutters arranged on the frame. At least two adjacent shutters are arranged one after the other along a first axis to reversibly and rigidly co-operate with one another, such that a movement exerted on either of the two shutters is transmitted to the other of the shutters.