Sliding Active Air Flap Layout for Grill-Integrated Cooling Control
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Solution Overview
Problem
Active air flaps for vehicles face challenges in reducing air resistance at high speeds while maintaining effective cooling at low speeds, leading to reduced fuel efficiency and potential interference with bumper flanges due to their design.
Innovation Solution
An active air flap apparatus with a frame coupled to the rear surface of a grill, featuring a pair of flap portions that slide to open or close the air inlet, guided by a gear unit and actuator, allowing for efficient operation and integration with the grill surface, minimizing protrusion and torque requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flap portion protrudes to the outside of the bumper to enable easy rotation, then the ease of operation is improved, but the device complexity and potential interference with bumper flange increase
Solution Approach 1:
The patent transitions from a rotation-based mechanism (requiring protrusion) to a sliding mechanism moving along guide members. The flap portion moves horizontally along guide grooves rather than rotating, eliminating the need to protrude outside the bumper while maintaining operational capability. This dimensional change in movement approach resolves the conflict between ease of operation and device complexity.
2Device complexity
If a cantilever structure is used to prevent protrusion, then the device complexity is reduced, but the torque of the actuator increases due to traveling pressure
Solution Approach 1:
The patent divides the flap portion into multiple segments (first flap member and second flap member) connected by a connection portion. This segmentation allows the structure to better distribute and withstand traveling pressure, reducing the torque requirement for the actuator while preventing protrusion. The segmented design with guide members provides mechanical advantage in handling aerodynamic forces.
3Ease of operation
If the flap portion is rotated 90 degrees to open or close the air inlet, then the ease of operation is improved, but the device complexity and space requirements increase
Solution Approach 1:
Instead of rotating the flap portion 90 degrees to achieve opening and closing, the patent inverts the approach by using a sliding mechanism where the flap moves horizontally along guide members. The connection portion rotates slightly while the overall motion is linear sliding, not rotational. This inversion of the movement paradigm reduces space requirements and device complexity while maintaining operational simplicity.
Data Source
AI summary
The present disclosure relates to an active air flap apparatus, and the active air flap apparatus includes a frame coupled to a rear surface of a grill in which an air inlet is formed, a flap portion slidably coupled to an inside of the frame to open or close the air inlet formed in the grill, an actuator coupled to an outside of the frame to transmit power to the flap portion to open or close the air inlet, and a gear unit configured to transmit the power generated from the actuator to the flap portion, in which the flap portion is provided as a pair of flap portions, and when the air inlet is closed, the pair of flap portions close an upper region and a lower region of the air inlet while a distance between end portions in a direction toward the air inlet increases.