Snap-Fit Flap Assembly for Motor Vehicle Fan Units
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Solution Overview
Problem
The existing assembly processes for motorized fan units in motor vehicles are complex and costly, requiring intricate assembly methods that complicate quick assembly and automation, especially due to the need for robust connecting means that maintain flaps under high air pressure.
Innovation Solution
The use of snap-fastening connecting means, comprising an axis and a gutter that pivot around the axis, allows for easy assembly of movable flaps on the frame, reducing the complexity and cost of production while enabling automation, even for multiple flaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust connecting means are used to maintain flaps under high air pressure, then reliability is improved, but device complexity increases
Solution Approach 1:
The connecting means is divided into two separate components: a lug that protrudes from the flap and a corresponding receptacle in the frame. This segmentation allows each component to be simple in structure while their combination provides robust connection under high air pressure, eliminating the need for complex multi-part connecting mechanisms.
Solution Approach 2:
Instead of inserting the flap into the frame through complex molding operations, the invention inverts the assembly approach by having the lug protrude from the flap and snap into the frame's receptacle. This reversal simplifies both the connecting means structure and the assembly process while maintaining reliability under pressure.
2Reliability
If complex connecting means are used to ensure robust flap connection, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The connecting means is segmented into a lug and receptacle, both of which can be molded as simple integral features of the flap and frame respectively. This avoids the need for complex multi-component connecting assemblies, reducing molding operations and manufacturing cost while ensuring robust connection.
Solution Approach 2:
The lug-receptacle connecting means serves multiple functions: it provides robust mechanical connection, enables simple snap-fit assembly, and requires no additional fasteners or complex mechanisms. This multi-functionality eliminates the need for separate connecting components, reducing manufacturing complexity and cost.
3Reliability
If traditional assembly methods are used for multiple flaps, then connection reliability is improved, but productivity decreases
Solution Approach 1:
Each flap is equipped with its own lug that independently snaps into the frame, allowing flaps to be assembled separately and quickly without requiring complex coordinated operations. This segmented approach enables parallel assembly of multiple flaps, significantly improving productivity while maintaining connection stability.
Solution Approach 2:
The lug is pre-formed as an integral part of the flap during flap manufacturing, and the receptacle is pre-formed in the frame. This preliminary preparation eliminates the need for complex assembly operations during final assembly, allowing quick snap-fit installation of multiple flaps while ensuring reliable connection.
4Reliability
If intricate assembly operations are used to attach flaps, then connection reliability is improved, but ease of operation decreases
Solution Approach 1:
The connecting means is segmented into a protruding lug on the flap and a receptacle in the frame, creating a simple snap-fit interface. This segmentation transforms complex intricate assembly operations into a single straightforward insertion and snap-action, dramatically improving ease of operation while maintaining attachment reliability.
Data Source
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AI summary
The invention relates to a device for assembling an electric fan unit, in particular for a motor vehicle, including a frame (10) for supporting said unit, said frame (10) including at least one opening (7) provided with a movable flap (6), the movable flap (6) being designed to control a passage of air through the opening (7) in the frame (10), and being movable between a closed position in which the flap (6) stops the air from passing and an open position in which the flap (6) allows the air to pass, the movable flap (6) being assembled with the frame (10) by one or more connecting means (8) acting as hinges, said device (1) being designed such that the movable flap (6) is mounted on the frame (10) by a snap-fitting operation in the connecting means or in each of said connecting means (8).