Patent Publication Number: US-2015072604-A1

Title: Active air flap system of vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority of Korean Patent Application Number 10-2013-0108067 filed Sep. 9, 2013, the entire contents of which application is incorporated herein for all purposes by this reference. 
     BACKGROUND OF INVENTION 
     1. Field of Invention 
     The present invention relates to an active air flap system of a vehicle and, more particularly, to an active air flap system of a vehicle in which a flap is prevented from being stuck due to failure of a motor, or the like, to thus prevent the interior of an engine compartment from overheating. 
     2. Description of Related Art 
     In general, a variety of heat exchangers such as a radiator, an intercooler, an evaporator, and a condenser, as well as components for driving a vehicle such as an engine, are provided within an engine compartment of a vehicle. 
     A heat-exchanging medium such as a refrigerant flows in the components so as to be heat-exchanged with ambient air of the heat exchangers to perform cooling or heat dissipation. Thus, in order to stably operate the variety of heat exchangers within the engine compartment of a vehicle, ambient air is required to be smoothly supplied to the engine compartment. 
     However, when a vehicle is running at a high speed, a large amount of ambient air is introduced at a high speed, increasing air resistance. Thus, vehicle fuel efficiency (or mileage) is degraded. 
     In order to address the problem, an active air flap system is used to make a large amount of air flow to the interior of an engine compartment when a vehicle is running at a low speed and make a relatively small amount of air flow to the interior of the engine compartment when the vehicle is running at a high speed, to thus enhance fuel efficiency. 
       FIG. 1  illustrates a related art active air flap system. As illustrated in  FIG. 1 , the active air flap system may be installed in a front end module of a vehicle and may include a duct  10  having an opening  12 , a motor  20  installed in a central portion of the duct  10 , and a flap  30  coupled to the motor  20  through a hinge. 
     The flap  130  is regulated in a rotation angle according to driving of the motor  20 , so when a vehicle is running at a low speed, the flap  130  opens the opening  12  to be large, and when the vehicle is running at a high speed, the flap  130  opens the opening  12  to be small. 
     In the related art active air flap system, however, since the motor  20  and the hinge are integrally coupled, when the motor  20  has an error due to an abnormal reason or when a battery supplying power to the motor  20  is dead, the flap  30  is stuck and not operated. 
     When the flap  30  is stuck and not operated, ambient air cannot flow into the engine compartment of the vehicle. Thus, an internal temperature of the engine compartment is increased to prevent the variety of heat exchangers provided within the engine compartment from operating normally. 
     The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art. 
     BRIEF SUMMARY 
     Various aspects of the present invention provide for an active air flap system having a novel structure having advantages of preventing an internal temperature of an engine compartment from being increased when a vehicle is running, by preventing a flap from being stuck to a motor. 
     Various aspects of the present invention provide for an active air flap system of a vehicle, including: a duct having an opening allowing ambient air to be introduced to the interior of an engine compartment of the vehicle; a motor provided in the duct, configure to generate driving force according to whether power is applied, and having a hinge shaft configured to transmit the generated driving force; and a flap coupled to the hinge shaft of the motor when power is applied to the motor, to regulate a degree of opening and closing of the opening by the driving force from the motor, and released from the state of being coupled to the hinge shaft of the motor when power supply to the motor is cut off, to open the opening. 
     The hinge shaft of the motor may be configured as an electromagnet to generate magnetic force according to whether power is applied thereto, and a bonding plate made of a metal may be provided in the flap to allow the flap to be selectively coupled to the hinge shaft according to magnetic force generated by the hinge shaft. 
     The flap may include: a fixed frame provided in the duct and having an insertion space formed therein; a moving frame selectively inserted into the insertion space of the fixed frame; a bonding plate made of a metal and provided in a surface of the moving frame facing the hinge shaft of the motor; and a main spring provided between the fixed frame and the moving frame and providing elastic force in a direction in which the moving frame is inserted into the insertion space of the fixed frame. 
     The moving frame may include: a main body having an insertion groove formed in at least one side thereof; a lateral body movably provided in the insertion groove; and a lateral spring provided between the main body and the lateral body and providing elastic force in a direction in which the lateral body is released from the insertion groove, wherein when the moving frame is inserted into the fixed frame, the lateral body is inserted into the insertion groove. 
     A sloped portion may be formed in a lateral surface of the lateral body facing the fixed frame. 
     The active air flap system may further include: a fixing unit provided between the fixed frame and the moving frame to prevent the moving frame from being released, when the moving frame is inserted into the insertion space of the fixed frame. 
     The fixing unit may include: a fixing hole formed in the moving frame; a hook provided of the fixed frame and inserted into the fixing hole when the moving frame is inserted into the insertion space of the fixed frame; and an elastic member providing elastic force in a direction in which the hook is inserted into the fixing hole. 
     The hook may be rotatably hinge-coupled to the fixed frame, and the elastic member may be a torsion spring provided in a portion in which the fixed frame and the hook are hinge-coupled. 
     The moving frame may be classified into a plurality of moving frames each having an insertion space formed therein, and each of the moving frames may be inserted into an insertion space of a moving frame that neighbors in a direction in which each of the moving frames is separated from the motor or the fixed frame. 
     Each of the moving frames may include: a main body inserted into the fixed frame or a neighbor moving frame and having an insertion groove formed in at least one side thereof; a lateral body inserted into the insertion groove and moving up and down; and a lateral spring provided between the main body and the lateral body and providing elastic force in a direction in which the lateral body is released from the insertion groove, wherein when the moving frame is inserted into the fixed frame, the lateral body is inserted into the insertion groove. 
     The active air flap system may further include: a fixing unit provided between the fixed frame and a moving frame closest to the motor in order to prevent the moving frame from being released when each moving frame is inserted into an insertion space of a rear neighbor frame or the fixed frame. 
     The fixing unit may include: a fixing hole formed in the moving frame closest to the motor; a hook provided in the fixed frame and inserted into the fixing hole when a forefront moving frame is inserted into the insertion space of the fixed frame; and an elastic member providing elastic force in a direction in which the hook is inserted into the fixing hole. 
     The hook may be rotatably hinge-coupled to the fixed frame, and the elastic member may be a torsion spring provided in a portion in which the fixed frame and the hook are hinge-coupled. 
     The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view illustrating a configuration of the related art active air flap system. 
         FIG. 2  is a plan view illustrating a configuration of a motor and a flap of the related art active air flap system. 
         FIG. 3(   a ) and  FIG. 3(   b ) are plan views illustrating a configuration of an exemplary active air flap system according to the present invention. 
         FIG. 4  is a plan view illustrating a coupling relationship between a motor and a flap of an exemplary active air flap system according to the present invention. 
         FIG. 5  is a perspective view illustrating an exemplary configuration of a second main body according to the present invention. 
         FIG. 6  is a perspective view illustrating an exemplary configuration of a second lateral body and second lateral springs according to the present invention. 
         FIG. 7  is a perspective view illustrating an exemplary configuration of a first main body according to the present invention. 
         FIG. 8  is a perspective view illustrating an exemplary configuration of a first lateral body and first lateral springs according to the present invention. 
         FIG. 9  is a perspective view illustrating an exemplary configuration of a fixed frame according to the present invention. 
         FIG. 10  is a plan view illustrating an exemplary configuration of a hook according to the present invention. 
         FIG. 11  is a view illustrating operational states (a) to (d) of an exemplary active air flap system according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims. 
     To clarify the present invention, portions irrespective of description are limited and like numbers refer to like elements throughout the specification. 
     Also, in the drawings, sizes and thickness of components are arbitrarily shown for the description purposes, so the present invention is not limited to the illustrations of the drawings and thicknesses are exaggerated to clearly express various parts and regions. 
       FIG. 3  is a plan view illustrating a configuration of an active air flap system according to various embodiments of the present invention.  FIG. 4  is a plan view illustrating a coupling relationship between a motor and a flap of the active air flap system according to various embodiments of the present invention. 
     As illustrated in  FIGS. 3 and 4 , the active air flap system according to various embodiments of the present invention includes a motor  120  installed in a duct  110  installed in a front end module of a vehicle, and a flap  130  coupled to both sides of the motor  120  to selectively open and close an opening  112  of the duct  110 . 
     The motor  120 , which generates driving force (or power) according to whether power is applied, is connected to the flap  130  through a hinge shaft  122 . Here, the hinge shaft  122  provided in the motor  120  is configured as an electromagnet. Thus, when power is supplied to the motor  120 , magnetic force is generated from the hinge shaft  122 . 
     The flap  130  is coupled to the hinge shaft  122  of the motor  120 , and a rotation angle of the flap  130  is regulated by driving force from the motor  120  to regulate an amount of opening and closing of the opening  112  formed in the duct  110 . Namely, when a vehicle is running at a low speed, the rotation angle of the flap  130  is increased to open the opening  112  wide. When the vehicle is running at a high speed, the rotation angle of the flap  130  is reduced to open the opening  112  a little. 
     When power is applied to the motor  120 , the flap  130  of the active air flap system according to various embodiments of the present invention is maintained in a state of being coupled to the hinge shaft  122  of the motor  120 . However, when power is not applied to the motor  120 , the flap  130  is released from the state of being coupled to the hinge shaft  122  of the motor  120  to open the opening  112  of the duct  110 . 
     In detail, the flap  130  includes a fixed frame  140  provided in the duct  110  and having an insertion space formed therein, moving frames  150  and  160  selectively inserted into the insertion space of the fixed frame  140 , an bonding plate  165  made of metal and provided in the side facing the hinge shaft  122  of the motor  120 , and a main spring  132  provided between the fixed frame  140  and the moving frames  150  and  160  to provide elastic force in a direction in which the moving frames  150  and  160  are inserted into the insertion space of the fixed frame  140 . 
       FIG. 9  is a perspective view illustrating a configuration of the fixed frame  140  according to various embodiments of the present invention.  FIG. 10  is a perspective view illustrating a configuration of a hook  170  according to various embodiments of the present invention. 
     As illustrated in the drawings, the fixed frame  140  has a shape of a square block having an insertion space  142  formed therein. The moving frames  150  and  160  are inserted into the insertion space  142 , reducing an overall length of the flap  130 . 
     The hook  170  is provided in the fixed frame  140  in order to fix the moving frame when the moving frame is inserted into the insertion space  142 . When the moving frame is inserted into the insertion space  142  of the fixed frame  140 , the hook  170  is inserted into a fixing hole  164  formed in the moving frame to prevent the moving frame from being released from the insertion space. 
     The hook  170  is hinge-coupled to an upper portion of the fixed frame  140  and rotatably installed. Here, a torsion spring is installed in the hinge-coupled portion. The torsion spring provides elastic force in a direction in which the hook  170  is inserted into the fixing hole  164  (in the clockwise direction on the basis of  FIG. 10 ). 
     The moving frame according to various embodiments of the present invention may be configured as plural. Thus, when a plurality of moving frames are provided, a length by which the moving frames are reduced may be adjusted as necessary. 
     Hereinafter, an example in which two moving frames are provided will be described. 
     As illustrated in  FIG. 4 , the moving frames  150  and  160  include a first moving frame  150  inserted into the insertion space  142  of the fixing frame  142  and having a first insertion space  152  and a second moving frame  160  inserted into the first insertion space  152  of the first moving frame  150 . 
       FIG. 7  is a perspective view illustrating a configuration of the first main body  151  according to various embodiments of the present invention.  FIG. 8  is a perspective view illustrating a configuration of a first lateral body  155  and first lateral springs according to various embodiments of the present invention. 
     As illustrated in the drawings, the first moving frame  150  includes the first main body  151  inserted into the insertion space  142  of the fixed frame  140 , having a first insertion space  152  formed therein, and having a first insertion groove  153  formed in upper and lower portions thereof, the first lateral body  155  inserted into the first insertion groove  153  and moving up and down, and first lateral springs  159  provided between the first main body  151  and the first lateral body  155  and providing elastic force in a direction in which the first lateral body  155  is released from the first insertion groove  153 . 
     The first main body  151  has a substantially rectangular shape and has the first insertion space  152  formed therein to allow the second moving frame  160  to be inserted therein. 
     The first lateral body  155  is selectively inserted into the first insertion groove  153  formed in the upper and lower portions of the first main body  151 . The first lateral body  155  has a substantially rectangular shape and includes a first sloped portion  156  formed in a portion thereof which is in contact with the fixed frame  140 . 
     When the first moving frame  150  is released from the fixed frame  140 , the first lateral body  155  is maintained in a state of being released from the first insertion groove  153  by means of the first lateral springs  159 . Namely, when the first moving frame  150  is released from the fixed frame  140 , the first lateral body  155  of the first moving frame  150  is maintained in a state of being supported by the fixed frame  140 . 
     However, when the first moving frame  150  is inserted into the fixed frame  140 , the first lateral body  155 , being pressed by a front end of the fixed frame  140 , is inserted into the first insertion groove  153 . In other words, when power is not applied to the motor  120  so magnetic force is not generated from the hinge shaft  122 , the first moving frame  150  is inserted into the insertion space of the fixed frame  140  by elastic force of the main spring  132 . At this time, as the first sloped portion  156  of the first lateral body  155  is pressed by the front end of the fixed frame  140 , the first lateral body  155  is moved downwardly. Accordingly, the first lateral body  155  is inserted into the first insertion groove  153 , and the first moving frame  150  is inserted into the insertion space of the fixed frame  140 . 
       FIG. 5  is a perspective view illustrating a configuration of a second main body  161  according to various embodiments of the present invention.  FIG. 6  is a perspective view illustrating a configuration of a second lateral body  165  and second lateral springs  169  according to various embodiments of the present invention. 
     As illustrated in the drawings, the second main body  161  and the second lateral body  165  have shapes similar to those of the first main body  151  and the first lateral body  155 , respectively. 
     In detail, the second moving frame  160  includes the second main body  161  inserted into the first moving frame  150  and having a second insertion groove  163  formed upper and lower portions thereof, the second lateral body  165  inserted into the second insertion groove  163  and moving up and down, and second lateral springs  169  provided between the second main body  161  and the second lateral body  165  and providing elastic force in a direction in which the second lateral body  165  is released from the second insertion groove  163 . 
     The second main body  161  may have a substantially rectangular shape and may have an insertion space formed therein to allow the main spring  132  to be inserted therein. 
     The second lateral body  165  is selectively inserted into the second insertion groove  163  formed in the upper and lower portions of the second main body  161 . The second lateral body  165  has a substantially rectangular shape and has a second sloped portion  166  formed in a portion thereof which is in contact with the first moving frame  150 . 
     When the second moving frame  160  is released from the first moving frame  150 , the second lateral body  165  is maintained in a state of being released from the second insertion groove  163  by means of the second lateral spring  169 . Namely, when the second moving frame  160  is released from the first moving frame  150 , the second lateral body  165  of the second moving frame  160  is maintained in a state of being supported by the first moving frame  150 . 
     However, when the second moving frame  160  is inserted into the first moving frame  150 , the second lateral body  165 , being pressed by a front end of the first moving frame  150 , is inserted into the second insertion groove  163 . In other words, when power is not applied to the motor  120  so magnetic force is not generated from the hinge shaft  122 , the second moving frame  160  is inserted into the insertion space of the first moving frame  150  by elastic force of the main spring  132 . At this time, as the second sloped portion  166  of the second lateral body  165  is pressed by the front end of the first moving frame  150 , the second lateral body  165  is moved downwardly. Accordingly, the second lateral body  165  is inserted into the second insertion groove  163 , and the second moving frame  160  is inserted into the insertion space of the first moving frame  150 . 
     The bonding plate  165  made of a metal is provided in a surface of the second moving frame  160  facing the hinge shaft  122  of the motor  120 . The bonding plate  165  is selectively coupled to the hinge shaft  122  of the motor  120 . Namely, when power is applied to the motor  120 , magnetic force is generated from the hinge shaft  122  to attract the bonding plate  165  to allow the hinge shaft  122  of the motor  120  and the flap  130  to be coupled. Accordingly, driving force from the motor  120  is transmitted to the flap  130 . 
     However, when power supply to the motor  120  is cut off, magnetic force is not generated from the hinge shaft  122 . Thus, the flap  130  is released from the motor  120 . 
     Hereinafter, an operation of the active air flap system according to various embodiments of the present invention will be described. 
       FIG. 11  is a view illustrating an operational state of the active air flap system according to various embodiments of the present invention. 
     As illustrated in  FIG. 11(   a ), when power is applied to the motor  120 , magnetic force is generated from the hinge shaft  122 , of the motor  120 , configured as an electromagnet. Thus, the bonding plate  165  provided in the second moving frame  160  is attracted to allow the flap  130  to be coupled to the hinge shaft  122  of the motor  120 . The motor  120  operates upon receiving power from a battery of the vehicle. 
     Thus, when the hinge shaft  122  of the motor  120  rotates, the flap  130  is rotated according to frictional contact of the hinge shaft  122  and the bonding plate  165 . 
     Thereafter, as illustrated in  FIG. 11(   b ), when power is not supplied to the motor  120  due to an abnormal reason or when power is not supplied to the motor  120  because the battery is dead, magnetic force is not generated from the hinge shaft  122 , of the motor  120 , configured as an electromagnet. Thus, the coupling of the hinge shaft  122  of the motor  120  and the bonding plate  165  provided in the second moving frame  160  is released. 
     Thereafter, as illustrated in  FIG. 11(   c ), the first moving frame  150  is inserted into the insertion space of the fixed frame  140  due to elastic force of the main spring  132 , and the second moving frame  160  is sequentially inserted into the insertion space of the first moving frame  150 . 
     When the second moving frame  160  is inserted into the first moving frame  150  and the first moving frame  150  is inserted into the fixed frame  140 , the hook  170  provided in the fixed frame  140  is inserted into the fixing hole  164  of the second moving frame  160 . Thus, the flap  130  may be stably maintained in a reduced state. 
     In this manner, as the overall length of the flap  130  is reduced, it is completely released from the hinge shaft  122  of the motor  120 . Also, as the overall length of the flap  130  is reduced, the opening  122  of the duct  110  is opened. Accordingly, ambient air may be introduced into the interior of the engine compartment even while the vehicle is running, the engine compartment can be prevented from overheating. 
     Finally, as illustrated in  FIG. 11(   d ), when the motor  120  is repaired or the battery is exchanged so power is normally supplied to the motor  120 , the hook  170  provided in the fixed frame  140  is released from the fixing hole  165  of the second moving frame  160 . When power is supplied to the motor  120 , the hinge shaft of the motor  120  generates magnetic force, and thus, the bonding plate  165  provided in the second moving frame  160  is coupled to the hinge shaft. Thus, the flap  130  is restored into its original state and the driving force of the motor  120  may be transmitted to the flap  130 . 
     So far, the active air flap system according to various embodiments of the present invention has been described. In various embodiments of the present invention, the case in which the flap  130  has two moving frames has been described. However, the present inventive concept is not necessarily limited thereto and only a single moving may be provided or three or more moving frames may be provided, as necessary. 
     According to various embodiments of the present invention described above, when power is not applied to the motor of the active air flap system due to an abnormal reason, the flap is separated from the motor so as to be prevented from being stuck due to fault of the motor resulting from an abnormal reason or due to a dead battery. 
     In addition, since the flap is prevented from being stuck, although power is not applied to the motor, ambient air is introduced to the interior of the engine compartment of a vehicle, whereby an internal temperature of the engine compartment is prevented from being increased while the vehicle is running. 
     For convenience in explanation and accurate definition in the appended claims, the terms upper or lower, front or rear, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures. 
     The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.