Radiator Air Intake Structure for Pedestrian Impact and Vibration
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Solution Overview
Problem
Existing air inlet devices for motor vehicle radiators do not adequately address pedestrian impact safety while being simple to manufacture and implement, often requiring complex structures and high manufacturing costs to avoid forming hard points during frontal impacts.
Innovation Solution
An air inlet device with a deformable zone behind the bumper skin that dissipates impact forces, featuring a rigid zone to reduce vibrations and a crenellated or sinusoidal deformable zone for energy absorption, produced using injection overmolding with plastic materials, and a flexible seal to prevent air leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid air intake device is used to reduce vibrations, then vibration resistance is improved, but pedestrian impact safety deteriorates due to hard point formation
Solution Approach 1:
The air intake device is divided into a rigid zone (frame structure) and a deformable zone (impact-absorbing section). The rigid zone maintains structural integrity and reduces vibrations, while the deformable zone is positioned at the front to absorb impact forces during pedestrian collisions, preventing hard point formation.
Solution Approach 2:
Different zones of the air intake device have different mechanical properties: the frame structure is rigid for vibration resistance, while the front portion includes a deformable zone with reduced wall thickness or different material properties to provide compliance during pedestrian impact, creating localized quality variations.
2Object-affected harmful factors
If a deformable structure is used to absorb impact forces, then pedestrian impact safety is improved, but structural rigidity deteriorates leading to increased vibrations
Solution Approach 1:
The device is segmented into distinct rigid and deformable zones. The deformable zone absorbs impact forces through controlled deformation, while the rigid frame structure behind it maintains structural integrity and minimizes vibrations during normal operation.
Solution Approach 2:
The structure transitions from a deformable front zone with compliance to a rigid rear zone for stability. This local quality variation allows the front to be soft for safety while the rear remains stiff for vibration control.
3Object-affected harmful factors
If a complex mechanism is used to retract the air duct during impact, then pedestrian impact safety is improved, but device complexity increases
Solution Approach 1:
The complex rod mechanism for duct retraction is extracted and replaced with a simpler deformable zone integrated directly into the air intake device structure. The deformable zone passively absorbs impact forces through its material or geometric design, eliminating the need for active retraction mechanisms.
Solution Approach 2:
Instead of using a complex mechanical system, the patent employs a simple deformable structure that absorbs impact energy through controlled deformation. This approach uses a less complex, more cost-effective solution that achieves the same safety objective without requiring sophisticated mechanisms.
4Ease of manufacture
If the air intake device is made entirely rigid, then manufacturing simplicity is improved, but pedestrian impact safety deteriorates due to hard point formation
Solution Approach 1:
The air intake device uses local quality variation where the front zone has reduced wall thickness or different material properties to create a deformable region, while the rest of the structure remains rigid. This localized modification is achieved through simple manufacturing techniques like injection molding variations, maintaining ease of manufacture while improving safety.
Solution Approach 2:
The wall thickness or material parameters are changed in the front zone of the air intake device to create a deformable region. This parameter modification is integrated into the manufacturing process, allowing the device to be produced in a single operation with varying local properties, maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively meets pedestrian impact test constraints by dissipating impact forces and preventing hard points, while being simpler and less costly to produce, with improved airflow guidance and reduced noise from air flow.
Implementation Method 1
a deformable zone in the event of an impact which is intended to be arranged just behind the bumper skin. In the event of an impact of the pedestrian type, the deformable zone of the air intake device makes it possible to dissipate part of the forces generated by the impact
Implementation Method 2
The rigid zone of the frame of the air intake device makes it possible to stiffen the latter and to reduce the vibrations caused by the flow of air entering during the movement of the vehicle
Data Source
Figure 1~2
Figure 3
AI summary
Disclosed is an air intake device (16) for a radiator of a motor vehicle, the device comprising a frame with a front edge (18) intended to be mounted in contact with a bumper skin of the motor vehicle, and a rear edge (20) intended to be fastened to a radiator of the motor vehicle; the frame further comprising at least one wall extending in a transverse direction of the device, between the front edge and the rear edge, so as to form an air duct. At least one wall comprises a rigid zone (22) extending from the rear edge, and a deformable zone (24), which is capable of deforming in the event of an impact, comprises means for promoting its deformation and extends from the front edge.