Nested Reinforcement Bars for Vehicle Grille Stiffness
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Solution Overview
Problem
Existing motor vehicle grille systems lack sufficient reinforcement for improved aerodynamics and structural integrity, particularly in vehicles with vertically aligned front bumpers and grilles, which can lead to reduced stiffness and increased drag.
Innovation Solution
A stacked reinforcement assembly is introduced, featuring a first set of bars nested within a second set, providing rigidity and compactness, with the bars made of polymer and metallic materials, and connected via brackets for easy assembly and mounting to the active grille shutter assembly and vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement assembly is added to improve structural integrity and aerodynamics, then the stiffness and drag reduction are improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The reinforcement assembly employs a nested bar structure where a first bar is positioned within a second bar, creating a compact stacked arrangement. This nesting principle allows multiple reinforcement elements to be integrated in a space-efficient manner, providing enhanced structural integrity without proportionally increasing the overall assembly complexity or footprint.
Solution Approach 2:
The reinforcement assembly is divided into discrete modular components including multiple bars, brackets, and fasteners. This segmentation allows for simplified manufacturing, easier quality control, and more manageable assembly procedures, thereby reducing the practical complexity despite the enhanced structural capability.
2Stability of the object's composition
If multiple bars are used to provide reinforcement, then the rigidity is improved, but the volume and assembly complexity increase
Solution Approach 1:
The first bar is nested within the second bar, creating a compact stacked reinforcement structure. This nesting arrangement provides the rigidity of multiple bars while minimizing the overall volume occupied by the reinforcement assembly, as the bars are arranged concentrically rather than requiring separate spatial volume.
3Volume of stationary object
If a nested bar structure is used to reduce volume, then the compactness is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Brackets and fasteners are introduced as intermediary components that facilitate the connection between the nested bars and the grille structure. These intermediaries provide alignment features and mounting interfaces that simplify the nesting process, reducing the direct precision requirements between the bars themselves while maintaining the compact volume benefits.
4Loss of energy
If reinforcement assembly is added to improve aerodynamics, then the drag reduction is improved, but the weight of the vehicle increases
Solution Approach 1:
The reinforcement assembly utilizes a composite construction combining metallic bars (providing structural strength) with polymer or plastic components (reducing weight). This composite material approach allows the assembly to provide the necessary aerodynamic reinforcement for drag reduction while minimizing the weight penalty through the use of lighter-weight materials for non-critical structural elements.
Data Source
AI summary
This disclosure relates to a stacked reinforcement assembly for a grille of a motor vehicle. An example vehicle includes a fascia, an active grille shutter assembly including a housing, and a reinforcement assembly connected to the fascia and the housing. The reinforcement assembly includes a first bar at least partially nested within a second bar. An assembly and method are also disclosed.