Slotted Grill Assembly With Deformable-Wall Load-Bearing Joints
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Solution Overview
Problem
Existing grill assemblies, particularly in vehicle and ventilation applications, lack rigidity and mounting interfaces to support additional assemblies, and are often produced using materials and dimensions not suitable for bearing external loads, leading to high production costs and limited flexibility in manufacturing.
Innovation Solution
The use of deformable walls at intersections between grill panels, combined with mounting interfaces for structural frame members, allows for the secure attachment of grill assemblies and additional assemblies, enhancing rigidity and enabling cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used for high quantity production, then production efficiency is improved, but initial tooling cost increases and production flexibility decreases
Solution Approach 1:
The grill assembly is divided into multiple individual panels that can be manufactured separately using simple tools and then assembled together using the deformable wall joining mechanism. This segmentation allows each panel to be produced with basic equipment while the overall assembly achieves high production rates through efficient joining.
Solution Approach 2:
The deformable wall mechanism changes the physical state of the joining process by deforming the wall material from its original configuration to a locked position. This parameter change enables a simple, tool-free joining method that achieves strong connections without complex tooling, resolving the contradiction between production efficiency and tooling complexity.
2Weight of moving object
If lightweight materials are used for grill construction, then weight is reduced, but structural strength to support external assemblies decreases
Solution Approach 1:
The deformable wall is designed with a curved configuration that provides structural strength while using minimal material. The curved geometry naturally resists applied loads and distributes stresses effectively, allowing lightweight materials to achieve the necessary load-bearing capacity to support external assemblies like emitters or sensors.
Solution Approach 2:
The grill assembly combines lightweight panel materials with the deformable wall joining mechanism to create a composite structure. The deformable wall acts as both a joining element and a structural reinforcement, enabling the overall assembly to support external loads while maintaining low weight through the use of lightweight base materials.
3Ease of manufacture
If simple panel designs are used without additional interfaces, then manufacturing simplicity is improved, but adaptability to support different assemblies decreases
Solution Approach 1:
The deformable wall serves multiple functions: it acts as the primary joining mechanism between panels, provides structural reinforcement, and creates a standardized interface that can accommodate various external assemblies. This multi-functionality allows the same simple panel design to be adapted to different applications by attaching different assemblies to the standardized deformable wall interface.
4Stability of the object's composition
If rigid joining methods are used to secure panels, then structural stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The deformable wall joining mechanism is designed to be self-servicing, where the panels themselves provide the joining function through the deformable wall's ability to bend and lock into position. No external fasteners, adhesives, or complex joining devices are required—the panels perform their own joining function through the inherent properties of the deformable wall, achieving stable connections with minimal manufacturing complexity.
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
This solution provides a cost-effective and flexible method for manufacturing grill assemblies that are rigid enough to support external loads, allowing for lower production rates while maintaining structural integrity and enabling various assembly configurations.
Implementation Method 1
grill panels are secured relative to each other using one deformable wall at each intersection of panels
Data Source
AI summary
Several grill assemblies and methods for assembling the same are claimed and disclosed. In one embodiment, the assembly includes slotted panels with a single deformable wall to fix the slotted panels together. In another embodiment, slotted panels are fixed together using two deformable walls, one deformed subsequently after the other. The general shape of panels and grill assemblies is disclosed. Features of grill assembly members used to mount the grill to separate structural frame members and mount separate assemblies to the grill assembly are also disclosed.