U.S. patent application number 15/889285 was filed with the patent office on 2019-08-08 for vehicular duct system and duct support method utilizing a supportive and compliant skeleton.
The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to David Brian Glickman, Ken Osuagwu, Corey Ross.
Application Number | 20190241061 15/889285 |
Document ID | / |
Family ID | 67476364 |
Filed Date | 2019-08-08 |
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United States Patent
Application |
20190241061 |
Kind Code |
A1 |
Ross; Corey ; et
al. |
August 8, 2019 |
VEHICULAR DUCT SYSTEM AND DUCT SUPPORT METHOD UTILIZING A
SUPPORTIVE AND COMPLIANT SKELETON
Abstract
An exemplary vehicular duct system includes, among other things,
a duct wall of a first material composition, and a skeleton of a
different, second material composition that is at least partially
embedded within the duct wall. The skeleton is more compliant to an
amount of force applied in a first direction than to the amount of
force applied in a second direction that is perpendicular to the
first direction. An exemplary duct support method includes, among
other things, supporting a duct wall having a first material
composition with a skeleton having a different, second material
composition. At least a portion of the skeleton is embedded within
the duct wall. The skeleton is more compliant to an amount of force
applied in a first direction than a second direction perpendicular
to the first direction.
Inventors: |
Ross; Corey; (Detroit,
MI) ; Glickman; David Brian; (Southfield, MI)
; Osuagwu; Ken; (Farmington Hills, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
67476364 |
Appl. No.: |
15/889285 |
Filed: |
February 6, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 19/48 20130101;
B60R 21/34 20130101; B60K 11/08 20130101; B60K 11/085 20130101;
B60R 19/52 20130101; B60Y 2306/01 20130101; B60R 2019/486 20130101;
B60R 2021/343 20130101; B60R 2019/525 20130101 |
International
Class: |
B60K 11/08 20060101
B60K011/08; B60R 19/52 20060101 B60R019/52; B60R 21/34 20060101
B60R021/34 |
Claims
1. A vehicular duct system, comprising: a duct wall of a first
material composition, the duct wall providing a duct opening that
conveys a flow of air to an engine compartment of a vehicle; and a
skeleton of a different, second material composition that is at
least partially embedded within the duct wall, the skeleton more
compliant to an amount of force applied in a first direction than a
second direction perpendicular to the first direction, the first
direction extends along a longitudinal axis of the vehicle and is
directed toward a front of the vehicle, wherein the second
direction is directed toward a laterally facing side of the
vehicle.
2. The assembly of claim 1, wherein the skeleton is more compliant
to the amount of force applied in the first direction than a third
direction that is perpendicular to both the first and second
directions.
3. The assembly of claim 1, wherein the first material composition
includes more rubber than the second material composition.
4. The assembly of claim 1, wherein the first and second material
compositions are both polymer based.
5. The assembly of claim 1, wherein the first material composition
is a fabric.
6. The assembly of claim 1, wherein the duct wall is overmolded
about at least a portion of the skeleton.
7. The assembly of claim 1, wherein the skeleton is a latticed
structure, at least a portion of the duct wall extends through
openings of the latticed structure.
8. The assembly of claim 1, wherein the duct wall extends
circumferentially continuously about an entire perimeter of the
duct opening.
9. The assembly of claim 8, further comprising a plurality of
active grille shutters, the duct opening conveying the flow of air
directly to the plurality of active grille shutters.
10. (canceled)
11. A vehicular duct system, comprising: a duct wall of a first
material composition; and a skeleton of a different, second
material composition that is at least partially embedded within the
duct wall, the skeleton more compliant to an amount of force
applied in a first direction than a second direction perpendicular
to the first direction, wherein the skeleton includes a plurality
of V-shaped structures having arms that are compressed together in
response to the amount of force.
12. The assembly of claim 11, wherein the arms of each of the
plurality of V-shaped structures meet at an apex facing a duct
opening provided by the duct wall.
13. The assembly of claim 12, wherein ends of the arms opposite the
apex connect to a beam structure of the skeleton.
14. A duct support method, comprising: supporting a duct wall
having a first material composition with a skeleton having a
different, second material composition, at least a portion of the
skeleton embedded within the duct wall, the skeleton more compliant
to an amount of force applied in a first direction than a second
direction perpendicular to the first direction; and compressing
together arms of a plurality of V-shaped structures formed in the
skeleton in response to the amount of force applied in the first
direction.
15. The method of claim 14, further comprising overmolding the duct
wall about the portion of the skeleton to embed the portion within
the duct wall.
16. The method of claim 15, wherein the skeleton is a latticed
structure, and at least a portion of the duct wall extends through
openings of the latticed structure during the overmolding.
17. The method of claim 14, further comprising passing a flow of
air through a duct opening provided by the duct wall to an engine
compartment of a vehicle, the duct wall extending circumferentially
continuously about an entire perimeter of the duct opening.
18. The method of claim 17, passing the flow of air from the duct
wall directly to a plurality of active grille shutters, and then to
the engine compartment.
19. The method of claim 17, wherein the first direction extends
along a longitudinal axis of the vehicle and is directed toward a
front of the vehicle, wherein the second direction is directed
toward a laterally facing side of the vehicle.
20. (canceled)
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to a duct of a vehicle
and, more particularly, to a duct incorporating a skeleton that
provides support to the duct while facilitating compliance of the
duct when loads are applied in certain directions.
BACKGROUND
[0002] Vehicles can incorporate various types of ducts that convey
air, for example. Design requirements may necessitate that the
ducts be somewhat compliant. The ducts could need to, for example,
flex away from a design position in response to a load applied in a
particular direction, and then return to the design position after
the load is removed. The load could be a load associated with
pedestrian protection, or a load resulting from the vehicle bumping
into an object.
[0003] One example duct is used to convey air from outside the
vehicle to an engine compartment of the vehicle. Such a duct could
be used in connection with an active grille shutter system at a
front of the vehicle. The duct may need to be compliant to meet
pedestrian protection requirements, but also rigid enough to
support the duct and surrounding structures without the duct
significantly sagging. Misalignment, trapping, and damage could
result from the duct sagging. Additionally, meeting desired design
clearances to surrounding components may be difficult if the duct
sags.
SUMMARY
[0004] A vehicular duct system according to an exemplary aspect of
the present disclosure includes, among other things, a duct wall of
a first material composition, and a skeleton of a different, second
material composition that is at least partially embedded within the
duct wall. The skeleton is more compliant to an amount of force
applied in a first direction than to the amount of force applied in
a second direction that is perpendicular to the first
direction.
[0005] In a further non-limiting embodiment of the foregoing
assembly, the skeleton is more compliant to the amount of force
applied in the first direction than to the amount of force applied
in a third direction that is perpendicular to both the first and
second directions.
[0006] In a further non-limiting embodiment of any of the foregoing
assemblies, the second material composition includes more rubber
than the first material composition.
[0007] In a further non-limiting embodiment of any of the foregoing
assemblies, the first and second material compositions are both
polymer based.
[0008] In a further non-limiting embodiment of any of the foregoing
assemblies, the first material composition is a fabric.
[0009] In a further non-limiting embodiment of any of the foregoing
assemblies, the duct wall is overmolded about a portion of the
skeleton.
[0010] In a further non-limiting embodiment of any of the foregoing
assemblies, the skeleton is a latticed structure. A portion of the
duct wall extends through openings of the latticed structure.
[0011] In a further non-limiting embodiment of any of the foregoing
assemblies, the duct wall provides a duct opening that conveys a
flow of air to an engine compartment of a vehicle. The duct wall
extends circumferentially continuously about an entire perimeter of
the duct opening.
[0012] A further non-limiting embodiment of any of the foregoing
assemblies includes active grille shutters. The duct opening
conveys the flow of air directly to the active grille shutters.
[0013] In a further non-limiting embodiment of any of the foregoing
assemblies, the first direction extends along a longitudinal axis
of the vehicle and is directed toward a front of the vehicle. The
second direction is directed toward a laterally facing side of the
vehicle.
[0014] In a further non-limiting embodiment of any of the foregoing
assemblies, the skeleton includes a plurality of V-shaped
structures having arms that are compressed together in response to
the amount of force.
[0015] In a further non-limiting embodiment of any of the foregoing
assemblies, the arms of each of the plurality of V-shaped
structures meet at an apex facing a duct opening provided by the
duct wall.
[0016] In a further non-limiting embodiment of any of the foregoing
assemblies, ends of the arms opposite the apex connect to a beam
structure of the skeleton.
[0017] A duct support method according to an exemplary aspect of
the present disclosure includes, among other things, supporting a
duct wall having a first material composition with a skeleton
having a different, second material composition. A portion of the
skeleton is embedded within the duct wall. The skeleton is more
compliant to an amount of force applied in a first direction than a
second direction perpendicular to the first direction.
[0018] A further non-limiting embodiment of the foregoing method
includes overmolding the duct wall about the portion of the
skeleton to embed the portion within the duct wall.
[0019] In a further non-limiting embodiment of any of the foregoing
methods, the skeleton is a latticed structure. At least a portion
of the duct wall extends through openings of the latticed structure
during the overmolding.
[0020] A further non-limiting embodiment of any of the foregoing
methods includes passing a flow of air through a duct opening
provided by the duct wall to an engine compartment of a vehicle.
The duct wall extends circumferentially continuously about an
entire perimeter of the duct opening.
[0021] A further non-limiting embodiment of any of the foregoing
methods includes passing the flow of air from the duct wall
directly to active grille shutters, and then to the engine
compartment.
[0022] In a further non-limiting embodiment of any of the foregoing
methods, the first direction extends along a longitudinal axis of
the vehicle and is directed toward a front of the vehicle. The
second direction is directed toward a laterally facing side of the
vehicle.
[0023] A further non-limiting embodiment of any of the foregoing
methods includes compressing together arms of a plurality of
V-shaped structures formed in the skeleton in response to the
amount of force applied in the first direction.
[0024] The embodiments, examples and alternatives of the preceding
paragraphs, the claims, or the following description and drawings,
including any of their various aspects or respective individual
features, may be taken independently or in any combination.
Features described in connection with one embodiment are applicable
to all embodiments, unless such features are incompatible.
BRIEF DESCRIPTION OF THE FIGURES
[0025] The various features and advantages of the disclosed
examples will become apparent to those skilled in the art from the
detailed description. The figures that accompany the detailed
description can be briefly described as follows:
[0026] FIG. 1 illustrates a front of a vehicle that includes an
exemplary embodiment of a duct system.
[0027] FIG. 2 illustrates an expanded view of the duct system from
the vehicle of FIG. 1.
[0028] FIG. 3 illustrates a close-up view of area 3 in FIG. 2
showing a portion of a wall from a duct of the duct system.
[0029] FIG. 4 illustrates a section view through the duct system of
FIG. 2.
[0030] FIG. 5 illustrates the section view of FIG. 4 when a load is
applied to the front of the vehicle.
[0031] FIG. 6 illustrates a close-up view of a portion of a wall
from a duct according to another exemplary embodiment.
[0032] FIG. 7 illustrates a close-up view of a portion of a wall
from a duct according to yet another exemplary embodiment.
[0033] FIG. 8 illustrates a close-up view of a portion of a wall
from a duct according to still another exemplary embodiment.
DETAILED DESCRIPTION
[0034] A duct of a vehicle may be required to be relatively
compliant to forces applied in a direction. To avoid sag, however,
the same duct may be required to be relatively rigid in other
directions.
[0035] This disclosure relates generally to a duct having a
skeleton structure. The skeleton permits the duct to be relatively
compliant when a force is applied to the duct in some directions.
The skeleton supports the duct to avoid, among other things,
undesirable sag in other directions. Pedestrian protection
requirements can necessitate forming the duct from soft shot
materials, which may be particularly prone to sag.
[0036] Referring to FIG. 1, an example vehicle 10 includes a
vehicular duct system 14 utilized to convey air from outside the
vehicle 10 to an engine compartment 18 of the vehicle 10. The
vehicle 10 could include other duct systems, such as air tubes.
[0037] The vehicle 10 extends along a longitudinal axis X. The
vehicle 10 extends laterally along an axis Y and vertically along
an axis Z. The axes X, Y, and Z are perpendicular to one
another.
[0038] The vehicular duct system 14, with reference to the
exemplary embodiment of FIG. 2, includes a fixed grille 22, a duct
system 26, and an active grille assembly 30. Air moving to the
engine compartment of the vehicle 10 initially passes through the
fixed grille 22. The air next moves through a duct opening 34
provided by the duct system 26, and then through a plurality of
active grille shutters 38 held within a housing 42 of the active
grille shutter assembly 30. From the active grille assembly 30, the
air moves into the engine compartment 18. The active grille
shutters 38 can be rotated to control the flow of air to the engine
compartment 18. An actuator, such as a motor (not shown), can be
used to selectively rotate the active grille shutters 38 to control
the flow of air to the engine compartment 18.
[0039] The fixed grille 22 provides a class-A surface for the
vehicle 10. The fixed grille 22 includes a plurality of fixed
shutters 46 in this example. In another example, the fixed shutters
46 can be omitted such that the air simply moves through an opening
provided by the fixed grille 22 or through some other structure.
The fixed grille 22 can be a fascia, or another type structure
forward of the duct system 26 and the active grille assembly
30.
[0040] In this example, the fixed grille 22, the duct system 26,
and the active grille assembly 30 are shown as separate structures.
In other examples, one or more of these components could be made
integral with one another, that is, the duct system 26 could extend
directly from the active grille shutter assembly 30 such that the
duct system 26 and the active grille shutter assembly 30 are
integrated together.
[0041] With reference now to FIGS. 3-5, and continued reference to
FIGS. 1 and 2, the duct system 26 includes a frame 50 and a
compliant assembly 54. The frame 50 is relatively rigid when
compared to the compliant assembly 54. When airflow, particularly
high velocity airflow, passes through the duct system 26, the
compliant assembly 54 can seal against other components to avoid
leakage of air.
[0042] In this exemplary non-limiting embodiment, the compliant
assembly 54 is fixed directly to the frame 50. Both the frame 50
and the compliant assembly 54 extend about an entire periphery of
the duct opening 34.
[0043] The compliant assembly 54 includes a duct wall 58 and a
skeleton 62. The duct wall 58 has a first material composition, and
the skeleton 62 has a different, second material composition. The
first material composition is a soft-shot material and compliant
when compared to the second material composition, which is a
hard-shot material. The soft-shot duct wall 58 can be overmolded
about the hard shot skeleton 623 in some examples.
[0044] In an exemplary non-limiting embodiment, the first material
composition and the second material composition are both
polymer-based, but the first material composition includes more
rubber than the second material composition. In another exemplary
embodiment, the first material composition is a fabric, and the
second material composition is polymer-based.
[0045] The skeleton 62 is a latticed structure comprising, in this
example, a plurality of openings 66. The duct wall 58, when the
duct wall 58 is a molded material, can be overmolded to the
skeleton 62 such that portions of the duct wall 58 extend through
the openings 66, and so that portions of the duct wall 58 are
overmolded about the skeleton 62. Passing material of the duct wall
58 through the openings 66 can integrate together the duct wall 58
and the skeleton 62 such that the duct wall 58 and the skeleton 62
are less likely to move relative to one another when a force is
applied to the compliant assembly 54.
[0046] In the exemplary embodiment, the skeleton 62 includes a
plurality of tabs 70 projecting from an outer surface 74 of the
duct wall 58. The tabs 70 can further integrate together movement
of the duct wall 58 and the skeleton 62.
[0047] In the exemplary embodiment, the skeleton 62 also includes
sections having a plurality of V-shaped structures 78. Each of the
V-shaped structures 78 has a pair of arms 82 extending from an apex
86 to one of a plurality of beam portions 90 of the skeleton
62.
[0048] Notably, the V-shaped structures 78 are oriented such that
when a sufficient force F is applied along the direction X from a
front of the vehicle 10 the arms 82 can fold or flex and, for a
given one of the V-shaped structures 78, move closer together. The
tabs 70, in addition to integrating together the duct wall 58 and
the skeleton 62 can help to ensure that the compliant assembly 54
folds and flexes together with the arms 82.
[0049] In FIG. 4, the compliant assembly 54 is in a design position
where the compliant assembly 54 extends a distance D.sub.1 from the
frame 50 in the X-direction toward a front of the vehicle 10. In
FIG. 5, the force F has been applied causing the compliant assembly
54 to fold and flex such that the compliant assembly extends a
distance D.sub.2 from the frame 50 toward the front of the vehicle
10. The distance D.sub.2 is less than the distance D.sub.1. The
compliant assembly 54 is thus compliant to the force F. Compliance
generally refers to the ability of the compliant assembly 54 to
deflect in response a given load.
[0050] The duct wall 58 moves together with the skeleton 62 as the
V-shaped structures 78 flex in response to the force F. When the
force F is removed, the arms 82 of the V-shaped structure 78 return
to a design position to return the duct wall 58 of the compliant
assembly 54 to the position of FIGS. 3 and 4.
[0051] The skeleton 62 is configured such that when the same amount
of force is applied to the compliant assembly 54 in a direction Z
or a direction Y, the duct wall 58 will not deflect as much as when
the amount of force was applied in the direction along the axis X
from the front of the vehicle 10.
[0052] The skeleton 62 is more compliant to the amount of force F
applied in the direction X from the front of the vehicle 10 than
the same amount of force applied in another direction perpendicular
to that direction. The skeleton 62 thus facilitates reducing
sagging of the compliant assembly 54 from a desired design
position, while still providing a structure complaint enough to
withstand the force applied in the direction X from the front of
the vehicle 10. The compliant assembly 54 may be required to comply
a certain amount in response to the force F to, for example, meet
pedestrian protection requirements.
[0053] In some examples, pedestrian protection requirements may
require the compliant assembly 54 to deflect more than a threshold
value in response to a leg form applying a force to the fixed
grille 22. The force applied to the fixed grille 22 by the leg form
could be up to 300 pounds in some examples.
[0054] Although described in connection with a force F applied in
the direction X from in front of the vehicle 10, other examples
could include skeletons designed to facilitate compliance of duct
walls in other directions. For example, if the duct is the air tube
20, the skeleton may need to facilitate compliance in the direction
Y when a force is applied from above the air tube 20, while
remaining relatively rigid in the X and Z directions.
[0055] The directionally varied compliance is due to, in the
exemplary embodiment, the V-shaped structures 78. Other structures
could be incorporated into the skeleton 62 to provide directionally
varied compliance in other examples.
[0056] In this disclosure, like reference numerals designate like
elements where appropriate, and reference numerals with the
addition of one-hundred or multiples thereof designate modified
elements. The modified elements incorporate the same features and
benefits of the corresponding modified elements, expect where
stated otherwise.
[0057] Referring now to FIG. 6, another exemplary compliant
assembly 154 includes a skeleton 162 at least partially embedded
within a duct wall 158. The skeleton 162 includes V-shaped
structures 178 each having an apex 186 pointing away from the duct
opening 34. The skeleton 162 includes a plurality of tabs 170 to
integrate together the skeleton 162 with the duct wall 158. The
skeleton 162 ensures that the compliant assembly 154 is compliant
to a force applied along a longitudinal axis of a vehicle while
still providing support to combat sagging.
[0058] Referring now to FIG. 7, yet another exemplary compliant
assembly 254 includes a skeleton 262 at least partially embedded
within a duct wall 258. The skeleton 262, in contrast to the
skeleton 162 of FIG. 6, includes tabs 270 on a side of the skeleton
262 facing the duct opening 34. The skeleton 262 includes a
plurality of tabs 270 to integrate together the skeleton 262 with
the duct wall 258. The skeleton 262 ensures that the compliant
assembly 254 is compliant to a force applied along a longitudinal
axis of a vehicle while still providing support to combat
sagging.
[0059] Referring now to FIG. 8, yet another exemplary compliant
assembly 354 includes a skeleton 362 that is substantially wholly
embedded within a duct wall 358. The skeleton 368 includes no tabs
extending away from the duct opening 34 or toward the duct opening
34. V-shaped structures 378 of the skeleton 362 includes respective
apexes 386 facing toward the duct opening 34. The skeleton 362
ensures that the compliant assembly 354 is compliant to a force
applied along a longitudinal axis of a vehicle while still
providing support to combat sagging.
[0060] Features of the disclosed examples include a duct system
incorporating a skeleton that supports a duct wall of the duct
system while facilitating compliance of the duct wall in certain
directions. Although described in connection with a duct wall of a
duct that communicates air to an active grille assembly, the
teachings of this disclosure could be used in combination with
other vehicular duct assemblies such as for example, dirty air
tubes.
[0061] In some examples, substantially the same injection molding
equipment can be used to mold the compliant assembly with the
skeleton, as well as a compliant assembly without the skeleton.
Thus, substantial tooling changes may not be required. Since the
skeleton can be integral with other portions of the duct wall,
additional packaging space to accommodate the skeleton may not be
required.
[0062] The preceding description is exemplary rather than limiting
in nature. Variations and modifications to the disclosed examples
may become apparent to those skilled in the art that do not
necessarily depart from the essence of this disclosure. Thus, the
scope of legal protection given to this disclosure can only be
determined by studying the following claims.
* * * * *