Patent Description:
In heat exchangers, a heat exchange medium generally flows therein. The heat exchange medium inside the heat exchanger and air outside the heat exchanger exchange heat with each other, and thus, cooling or heat radiating is performed.

In order to stably operate various heat exchangers in an engine room of a vehicle, external air is required to be smoothly supplied into the engine room.

However, when a vehicle travels at a high speed, a large amount of outside air is introduced at high speed, and thus, air resistance becomes very large. Therefore, there is a problem in that fuel efficiency of the vehicle is reduced.

To solve this problem, an active air flap (AAF) has been developed, which improves fuel efficiency by increasing an opening angle during low-speed traveling to increase an amount of air introduced into the engine room, and reducing the opening angle during high-speed traveling to reduce the amount of air inflow.

An active air flap includes a flap member, and the flap member is mounted on a rear surface of a grill and rotates to open or close an air inlet formed in the grill according to an operation of an actuator.

The air inlet is opened or closed according to the rotation of the flap member, and thus, external air is introduced through the air inlet or blocked.

Specifically, when the vehicle travels at high speed, the flap member closes the air inlet to reduce air resistance to improve fuel efficiency, and when the vehicle travels at low speed, the flap member opens the air inlet to allow air to flow into the engine room so as to cool the overheated engine room.

A flap portion constituting the active air flap is provided as a plurality of flap portions to open or close the air inlet.

In general, the plurality of flap portions are simultaneously operated by driving of an actuator, and thus, the plurality of flap portions are rotated.

Accordingly, in the plurality of flap portions, as a traveling pressure increases while a vehicle travels, a torque of the actuator rotating the flap portions inevitably increases.

A structure of the active air flap has one of various forms. <CIT> discloses an active air flap apparatus for a vehicle with the features of the preamble of present claim <NUM>. <CIT>, <CIT>, <CIT> and <CIT> disclose further active air flap apparatus for a vehicle.

Among the structures of the active air flap having one of various forms, in a case of a structure in which a rotating shaft is fixed to a central portion of a flap portion in a width direction, the flap portion is opened or closed by rotating <NUM> ° by the rotating shaft.

In this case, in order to easily rotate the flap portion, the flap portion should protrude to the outside of a bumper.

The present invention is directed to providing an active air flap apparatus for a vehicle according claim <NUM> capable of effectively operating an active air flap by integrating a front surface of a flap portion and a front surface of a grill and minimizing the influence of air when the active air flap is operated.

The above and other objects, advantages, and features of the present invention, and a method for achieving them will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings.

According to the present invention, there is provided an active air flap apparatus for a vehicle, including a frame coupled to a rear surface of a grill in which an air inlet is disposed, a plurality of flap portions coupled to an inside of the frame to open or close the air inlet and arranged in a vertical direction of the frame, an actuator coupled to an outside of the frame to generate power, a gear unit operated by the power generated from the actuator, and a connection unit connecting the plurality of flap portions and the gear unit to each other to operate the plurality of flap portions according to the operation of the gear unit.

The frame includes two vertical frames disposed to be spaced a distance from each other and two horizontal frames disposed on upper end portions and lower end portions of the vertical frames to connect the two vertical frames.

A guide groove, which guides an operation direction of the connection unit when the power of the actuator is generated, extends in the horizontal frame.

Each of the plurality of flap portions may include a body portion configured to open or close the air inlet and a coupling unit extending in a direction toward an engine room from a rear surface of the body portion and coupled to the connection unit.

The connection unit includes a rotation rod connected to the gear unit, a guide rod which is inserted into the guide groove and coupled to which the plurality of flap portions which are spaced from each other by a distance in a longitudinal direction, and a link unit, a number of which corresponds to that of the plurality of flap portions, connecting the rotation rod and the guide rod to each other.

The connection unit may further include a driven gear coupled to an end portion of the rotation rod and engaged with the gear unit to receive power from the gear unit and rotate the rotation rod.

A first end of the rotation rod may be coupled to the horizontal frame disposed on an upper side and a second end of the rotation rod may be coupled to the horizontal frame disposed on a lower side to connect the two horizontal frames to each other.

Each of the plurality of flap portions may include a body portion configured to open or close the air inlet, and a coupling unit extending in a direction toward an engine room from a rear surface of the body portion and coupled to the connection unit, in which the guide rod may pass through the coupling unit and be coupled to the flap portion.

The guide rod may be disposed adjacent to the flap portion, and the rotation rod may be spaced from the guide rod by a distance in a direction toward an engine room.

The link unit may include a first link member having one end fixed to the rotation rod and configured to rotate together with the rotation rod and a second link member having one end rotatably coupled to the first link member and the other end rotatably coupled to the guide rod.

A rotating shaft passing through the horizontal frame may be coupled to the actuator, and the actuator may be fixed outside the horizontal frame to transmit power to the gear unit.

The gear unit may include a pinion gear connected to an end portion of the rotating shaft and rotated by receiving the power from the actuator, a rack gear engaged with the pinion gear and the driven gear and configured to rotate the rotation rod according to the power of the actuator transmitted from the pinion gear, and a gear cover sealing the driven gear, the pinion gear, and the rack gear.

According to another embodiment of the present invention, there is provided an active air flap apparatus for a vehicle, including a frame coupled to a rear surface of a grill in which an air inlet is disposed, a plurality of flap portions coupled to an inside of the frame to open or close the air inlet and arranged in a vertical direction of the frame, an actuator coupled to an outside of the frame to generate power, a gear unit operated by the power generated from the actuator, and a connection unit connecting the plurality of flap portions and the gear unit to each other to operate the plurality of flap portions according to the operation of the gear unit, in which the plurality of flap portions constitute a plurality of flap units arranged in a horizontal direction.

The frame includes two vertical frames disposed to be spaced a distance from each other, and two horizontal frames disposed on upper end portions and lower end portions of the vertical frames to connect the two vertical frames. The flap unit may include a first unit disposed at a center of the horizontal frame in the horizontal direction, a second unit disposed on the horizontal frame spaced a distance from the first unit, and a third unit disposed on the horizontal frame in a direction opposite to the direction in which the first unit is disposed from the second unit.

The connection unit, which includes a rotation rod connected to the gear unit, a guide rod which is inserted into the guide groove and coupled to the plurality of flap portions which are spaced from each other by a distance in a longitudinal direction, and a link unit, a number of which corresponds to that of the flap portions, connecting the rotation rod and the guide rod to each other, may include a first connection unit connected to the first unit, a second connection unit spaced from the first connection unit by a distance and connected to the second unit, and a third connection unit spaced from the second connection unit by a distance in a direction opposite to a direction in which the first connection unit is disposed and connected to the third unit.

The gear unit may include a pinion gear connected to an end portion of the rotating shaft and rotated by receiving the power from the actuator, and a rack gear configured to selectively rotate the rotation rod according to the power of the actuator transmitted from the pinion gear, and the rack gear may include a gear base portion forming a body, a first gear disposed at the gear base and engaged with a driven gear of the first connection unit, a second gear disposed at a position of the gear base portion spaced apart from the first gear and selectively engaged with a driven gear of the second connection unit, and a third gear disposed at a position of the gear base portion spaced apart from the second gear by a distance greater than a distance between the first gear and the second gear and selectively engaged with a driven gear of the third connection unit.

The first unit, the second unit, and the third unit may be sequentially operated according to respective distances between the first gear engaged with the driven gear of the first connection unit, the second gear engaged with the driven gear of the second connection unit, and the third gear engaged with the driven gear of the third connection unit.

Embodiments of the present invention are provided to more completely explain the present invention to those of ordinary skill in the art, and the following embodiments may be modified into various other forms. The embodiments are provided so that this disclosure will be more thorough and complete. In addition, in the accompanying drawings, each component is exaggerated for convenience and clarity of description, and the same reference numerals refer to the same elements in the drawings. As used herein, the term "and/or" includes any one or all possible combinations of the listed items.

The terminology used herein is used to describe specific embodiments.

As used herein, the singular form may include the plural form unless the context clearly dictates otherwise. Moreover, as used herein, "comprise" and/or "comprising" refers to the presence of the recited shapes, numbers, steps, operations, members, elements, and/or groups thereof, and does not exclude the presence or addition of one or more other shapes, numbers, steps, operations, members, elements and/or groups thereof.

<FIG> is a front view illustrating a state in which an active air flap apparatus for a vehicle of the present invention closes a grill, <FIG> is a front view illustrating a state in which the active air flap apparatus for a vehicle of the present invention opens the grill, <FIG> is a perspective view illustrating the active air flap apparatus for a vehicle of the present invention when viewed in one direction, <FIG> is a perspective view illustrating the active air flap apparatus for a vehicle of the present invention when viewed in the other direction, <FIG> is a perspective view illustrating a frame of the active air flap apparatus for a vehicle of the present invention, <FIG> is a front view illustrating a front surface of the active air flap apparatus for a vehicle of the present invention, <FIG> is a perspective view illustrating a flap portion and a connection unit of the active air flap apparatus for a vehicle of the present invention, <FIG> is a plan view illustrating the flap portion and the connection unit coupled to a gear unit of the active air flap apparatus for a vehicle of the present invention, and <FIG> are operational views illustrating an operating state of the active air flap apparatus for a vehicle of the present invention.

Referring to <FIG> and <FIG>, the active air flap apparatus for a vehicle according to one embodiment of the present invention includes a frame <NUM>, a flap portion <NUM>, a connection unit <NUM>, and an actuator <NUM>, and a gear unit <NUM>.

The frame <NUM> has a quadrangle frame shape and is coupled to an air inlet region formed in the grill on a rear surface of the grill.

In addition, various components such as the flap portion <NUM>, the connection unit <NUM>, the actuator <NUM>, and the gear unit <NUM> may be coupled to the frame <NUM>.

The frame <NUM> is coupled to the rear surface of the grill by a screw-coupling method.

To this end, as illustrated in <FIG>, a plurality of fixing units <NUM> are formed on a periphery of the frame <NUM> to be spaced apart from each other along a perimeter of the frame <NUM>.

Then, a screw member passes through each of the fixing units <NUM> in a direction toward the grill and is coupled to the rear surface of the grill.

Accordingly, the frame <NUM> can be firmly fixed to the grill by the screw members passing through the fixing units <NUM> and coupled to the grill.

The frame <NUM> includes vertical frames <NUM> and horizontal frames <NUM>.

Referring to <FIG>, the vertical frames <NUM> includes two panels and are horizontally spaced apart from each other in the air inlet region of the grill rear surface.

The vertical frames <NUM> are disposed on both sides of the air inlet.

That is, when the vertical frames <NUM> are viewed from a front surface of the grill, the vertical frames <NUM> are covered by the grill and are not exposed to the outside.

Referring to <FIG>, the horizontal frames <NUM> include two panels and are vertically spaced apart from each other in the air inlet area of the grill rear surface.

In addition, the horizontal frames <NUM> are disposed on upper end portions and lower end portions of the two vertical frames <NUM> to connect the vertical frames <NUM> to each other.

Accordingly, the frame <NUM> is entirely formed in a quadrangular frame shape due to the vertical frames <NUM> and the horizontal frames <NUM>.

Moreover, the horizontal frames <NUM> are disposed at the upper and lower portions of the air inlet.

That is, when the horizontal frames <NUM> are viewed from the front surface of the grill, the horizontal frames <NUM> are covered by the grill and are not exposed to the outside.

A guide groove <NUM> is formed in the horizontal frame <NUM>.

The guide groove <NUM> is formed in the pair of horizontal frames <NUM> spaced apart from each other in the vertical direction, and when power of the actuator <NUM> is generated, the guide groove <NUM> guides an operation direction of the connection unit <NUM>.

Moreover, preferably, the guide groove <NUM> is provided as a plurality of guide grooves, and the guide grooves <NUM> are formed to be spaced apart from each other in the horizontal direction in the pair of horizontal frames <NUM> spaced by a distance in the vertical direction.

The guide groove <NUM> includes a horizontal portion <NUM> and an inclined portion <NUM>.

The horizontal portion <NUM> is formed in a longitudinal direction of the horizontal frame <NUM>, and the inclined portion <NUM> is formed to extend obliquely from an end portion of the horizontal portion <NUM> in the horizontal frame <NUM>.

Accordingly, when the connection unit <NUM> is positioned at the end portion of the horizontal portion <NUM> of the guide groove <NUM>, the flap portion <NUM> opens the air inlet, and when the connection unit <NUM> is positioned at the end portion of the inclined portion <NUM>, the flap portion <NUM> closes the air inlet.

Meanwhile, flap portions <NUM>, connection units <NUM>, actuators <NUM>, and gear units <NUM> coupled to the frame <NUM> may be formed horizontally symmetrically based on a central portion of the frame <NUM> as illustrated in <FIG>.

Hereinafter, in order to easily explain technical features of the present invention, example components formed on any one side based on the central portion of the frame <NUM> will be described.

The flap portions <NUM> open or close the air inlet formed on the grill as illustrated in the drawing.

When the flap portions <NUM> are opened while a vehicle travels, air is introduced through the air inlet from the outside of the grill to cool the engine room.

Accordingly, the flap portions <NUM> can effectively cool the inside of the engine room according to the opening or closing of flap portions <NUM>.

Moreover, the flap portions <NUM> are provided as a plurality of flap portions and are arranged to be spaced a distance from each other along the vertical direction of the vertical frame <NUM> to form a flap unit <NUM>.

Moreover, the grill is formed between the plurality of flap units <NUM> spaced apart from each other.

The flap units <NUM> are formed in a number and at positions corresponding to the guide grooves <NUM> spaced apart from each other in the horizontal direction in the horizontal frame <NUM>.

That is, the flap portions <NUM> are arranged in the vertical direction of the vertical frame <NUM> to form the flap units <NUM>, and the plurality of flap units <NUM> are arranged in the horizontal direction to correspond to the guide grooves <NUM>.

Each flap unit <NUM> includes a first unit 230_1, a second unit 230_2 and a third unit 230_3 as illustrated in <FIG> and <FIG>.

The first unit 230_1 is disposed at a center of the horizontal frame <NUM> in the horizontal direction.

The first unit 230_1 is disposed at a position corresponding to the guide groove <NUM>, which is formed at the center of the horizontal frame <NUM> in the horizontal direction, among the plurality of guide grooves <NUM> formed in the horizontal frame <NUM>, and slidably coupled to the corresponding guide groove <NUM>.

The second unit 230_2 is disposed in a position spaced apart from the first unit 230_1 in the horizontal frame <NUM>.

The second unit 230_2 is disposed at a position corresponding to the guide groove <NUM> formed at a position spaced apart from the guide groove <NUM>, to which the first unit 230_1 is coupled, among the plurality of guide grooves <NUM> formed in the horizontal frame <NUM> and slidably coupled to the corresponding guide groove <NUM>.

The third unit 230_3 is disposed in a direction opposite to the direction in which the first unit 230_1 is disposed from the second unit 230_2 in the horizontal frame <NUM>.

That is, the third unit 230_3 is disposed at an end portion of the horizontal frame <NUM> in the horizontal direction.

The third unit 230_3 is disposed at a position corresponding to the guide groove <NUM>, which is disposed in a direction opposite to the disposition direction of the guide groove <NUM> to which the first unit 230_1 is coupled from the guide groove <NUM> to which the second unit 230_2 is coupled, among the plurality of guide grooves <NUM> formed in the horizontal frame <NUM>, and slidably coupled to the corresponding guide groove <NUM>.

As described above, each of the plurality of flap portions <NUM> constituting the flap unit <NUM> includes a body portion <NUM> and a coupling unit <NUM>.

The body portion <NUM> constitutes a body of the flap portion <NUM>, and opens or closes the air inlet.

The body portion <NUM> has a shape corresponding to a shape of the air inlet formed on the grill.

The coupling unit <NUM> extends in a direction toward the engine room from a rear surface of the body portion <NUM>, and is coupled to the connection unit <NUM>.

Meanwhile, the flap portions <NUM> are arranged to be spaced a distance from each other in the vertical direction of the frame <NUM>, and thus, the coupling units <NUM> are arranged in the vertical direction and coupled to the connection unit <NUM>.

The connection unit <NUM> is formed in a number and at positions corresponding to the guide grooves <NUM> as illustrated in <FIG> and <FIG> and <FIG> and connects the flap portion <NUM> and the gear unit <NUM> to each other.

Moreover, the connection unit <NUM> operates the flap portion <NUM> according to the operation of the gear unit <NUM>.

The connection unit <NUM> includes a rotation rod <NUM>, a driven gear <NUM>, a guide rod <NUM>, and a link unit <NUM>.

The rotation rod <NUM> is connected to the gear unit <NUM>, spaced a distance from the guide rod <NUM> in the direction toward the engine room, and rotated according to the operation of the gear unit <NUM>.

In addition, the rotation rod <NUM> connects the pair of horizontal frames <NUM> spaced a distance from each other in the vertical direction.

Specifically, one end of the rotation rod <NUM> is coupled to the horizontal frame <NUM> disposed on the upper side, and the other end thereof is coupled to the horizontal frame <NUM> disposed thereunder.

Accordingly, the rotation rod <NUM> connects a pair of horizontal frames <NUM> spaced apart from each other in the vertical direction to each other.

Then, the driven gears <NUM> are coupled to both end portions of the rotation rod <NUM>.

The driven gears <NUM> are coupled to both end portions of the rotation rod <NUM> and engaged with the gear unit <NUM>.

Accordingly, the driven gear <NUM> rotates the rotation rod <NUM> according to the operation of the gear unit <NUM> when the gear unit <NUM> operates.

The driven gears <NUM> may be integrally formed with both end portions of the rotation rod <NUM>.

Accordingly, the driven gear <NUM> may securely transmit the power transmitted from the gear unit <NUM> to the rotating portion.

The guide rod <NUM> is disposed at a position spaced a distance from the rotation rod <NUM> in the direction in which the flap portion <NUM> is disposed inside the frame <NUM>.

That is, the guide rod <NUM> is disposed adjacent to the flap portion <NUM>.

In addition, both end portions of the guide rod <NUM> are slidably coupled to the guide grooves <NUM> formed in the pair of horizontal frames <NUM>.

In particular, the flap portions <NUM>, specifically, the coupling units <NUM> of the flap portions <NUM>, are coupled to the guide rod <NUM> spaced a distance from each other in the longitudinal direction of the guide rod <NUM>.

That is, the guide rod <NUM> passes through the coupling units <NUM> and is connected to the flap portions <NUM>.

Accordingly, when the guide rod <NUM> slides along the guide groove <NUM>, the flap portions <NUM> open or close the air inlet while moving along the guide rod <NUM>.

The link units <NUM> is formed in a number corresponding to that of the flap portions <NUM> and connect the rotation rod <NUM> and the guide rod <NUM> to each other.

Each of the link units <NUM> includes a first link member <NUM> and a second link member <NUM>.

One end of the first link member <NUM> is fixed to the rotation rod <NUM>, and the other end thereof is rotatably coupled to the second link member <NUM>.

Specifically, one end of the first link member <NUM> is integrally formed with the rotation rod <NUM>.

For this reason, the first link member <NUM> rotates together with the rotation rod <NUM> when the rotation rod <NUM> is rotated by the gear unit <NUM>.

A coupling protrusion <NUM> is formed on the first link member <NUM>.

The coupling protrusion <NUM> is formed on the other end of the first link member <NUM> and protrudes from one surface of the first link member <NUM>.

Preferably, the coupling protrusion <NUM> protrudes in a direction in which the second link member <NUM> is disposed.

Accordingly, the second link member <NUM> may be easily coupled to the coupling protrusion <NUM>.

One end of the second link member <NUM> is rotatably coupled to the first link member <NUM>, i.e., the coupling protrusion <NUM> formed on the other end of the first link member <NUM>, and the other end thereof is rotatably coupled to the guide rod <NUM>.

To this end, a coupling groove <NUM> and an insertion groove <NUM> are formed in the second link member <NUM>.

The coupling groove <NUM> is formed in one end of the second link member <NUM>, and the coupling protrusion <NUM> formed on the other end of the first link member <NUM> is rotatably coupled to the coupling groove <NUM>.

The insertion groove <NUM> is formed in the other end of the second link member <NUM>, and the guide rod <NUM> passes therethrough.

Meanwhile, preferably, the insertion groove <NUM> is disposed in a region that does not overlap the coupling unit <NUM> of the flap portion <NUM> rotatably coupled to the guide rod <NUM>.

In the connection unit <NUM> having this structure, in a case where the flap portions <NUM> open the air inlet, as illustrated in <FIG>, when the driven gear <NUM> is rotated counterclockwise based on <FIG> according to the operation of the gear unit <NUM>, the rotation rod <NUM> integrally fixed to the driven gear <NUM> is rotated counterclockwise together, and the first link member <NUM> fixed to the rotation rod <NUM> is rotated counterclockwise together with the rotation rod <NUM>.

In addition, one end of the second link member <NUM> having the other end rotatably coupled to the first link member <NUM> is rotatably coupled to the guide rod <NUM>, and thus, when the first link member <NUM> is rotated counterclockwise, the second link member <NUM> pulls the guide rod <NUM> in the rotational direction of the first link member <NUM>.

In this case, the guide rod <NUM> is slidably coupled to the guide groove <NUM> of the horizontal frame <NUM>. Therefore, when the guide rod <NUM> is pulled in the rotation direction of the first link member <NUM> by the second link member <NUM>, the guide rod <NUM> slides along the guide groove <NUM>.

In addition, the coupling unit <NUM> of the flap portion <NUM> is rotatably fixed to the guide rod <NUM>. Accordingly, when the guide rod <NUM> slides along the guide groove <NUM>, the flap portion <NUM> opens the air inlet while moving along the guide rod <NUM>.

For this reason, when the flap portion <NUM> opens the air inlet, the flap portion <NUM> slides along the guide groove <NUM> toward the rear surface of the grill, and thus, it is possible to prevent the flap portion <NUM> from protruding to the outside of the grill.

Conversely, when the flap portion <NUM> closes the air inlet, in a case where the flap portions <NUM> close the air inlet, as illustrated in the drawings, when the driven gear <NUM> is rotated clockwise based on <FIG> according to the operation of the gear unit <NUM>, the rotation rod <NUM> integrally fixed to the driven gear <NUM> is rotated clockwise together, and the first link member <NUM> fixed to the rotation rod <NUM> is rotated clockwise together with the rotation rod <NUM>.

In addition, one end of the second link member <NUM> having the other end rotatably coupled to the first link member <NUM> is rotatably coupled to the guide rod <NUM>, and thus, when the first link member <NUM> is rotated clockwise, the second link member <NUM> pushes the guide rod <NUM> in the rotational direction of the first link member <NUM>.

In this case, when the guide rod <NUM> is pushed in the rotational direction of the first link member <NUM> by the second link member <NUM>, the guide rod <NUM> slides along the guide groove <NUM>.

Accordingly, when the guide rod <NUM> slides along the guide groove <NUM>, the flap portion <NUM> closes the air inlet while moving along the guide rod <NUM>.

For this reason, when the flap portion <NUM> closes the air inlet, the front surface of the flap portion <NUM> in the outward direction of the vehicle and the front surface of the grill can be integrated.

Meanwhile, the connection unit <NUM> including the rotation rod <NUM>, the driven gear <NUM>, the guide rod <NUM>, and the link unit <NUM> includes a first connection unit 300_1, a second connection unit 300_2, and a third connection unit 300_3.

The first connection unit 300_1 is connected to the first unit 230_1 disposed on a horizontal end portion of the horizontal frame <NUM>.

Accordingly, the first connection unit 300_1 operates the flap portions <NUM> of the first unit 230_1 according to the operation of the gear unit <NUM>.

The second connection unit 300_2 is spaced a distance from the first connection unit 300_1 and is connected to the second unit 230_2 disposed to be spaced the distance from the first unit 230_1 in the horizontal frame <NUM>.

Accordingly, the second connection unit 300_2 operates the flap portions <NUM> of the second unit 230_2 according to the operation of the gear unit <NUM>.

The third connection unit 300_3 is spaced a distance from the second connection unit 300_2 in a direction opposite to the direction, in which the first connection unit 300_1 is disposed, and is connected to the third unit 230_3 disposed in the horizontal frame <NUM> in a direction opposite to the direction, in which the first unit 230_1 is disposed, from the second unit 230_2.

Accordingly, the third connection unit 300_3 operates the flap portions <NUM> of the third unit 230_3 according to the operation of the gear unit <NUM>.

As illustrated in <FIG> and <FIG>, the actuator <NUM> is coupled to the outside of the frame <NUM>, i.e., to the outside of the horizontal frame <NUM> disposed on the upper side, and generates power.

A rotating shaft <NUM> is coupled to the actuator <NUM>.

The rotating shaft <NUM> extends from the actuator <NUM> to the inside of the horizontal frame <NUM>.

Preferably, the rotating shaft <NUM> passes through the horizontal frame <NUM> disposed on the upper portion and the horizontal frame <NUM> disposed on the lower portion.

Accordingly, both ends of the rotating shaft <NUM> protrude from the outside of the horizontal frame <NUM>.

The rotating shaft <NUM> transmits the power generated from the actuator <NUM> to the gear unit <NUM>.

The gear unit <NUM> transmits the power generated from the actuator <NUM> to the flap portions <NUM>.

The gear unit <NUM> includes a pinion gear <NUM>, a rack gear <NUM>, and a gear cover <NUM>.

The pinion gear <NUM> is coupled to the end portion of the rotating shaft <NUM> passing through the horizontal frame <NUM> disposed on the upper portion and the horizontal frame <NUM> disposed on the lower portion.

Specifically, the pinion gear <NUM> is coupled to the end portion of the rotating shaft <NUM> protruding to the outside of the horizontal frame <NUM> disposed on the lower portion as illustrated.

Then, the pinion gear <NUM> is rotated by receiving the power of the actuator <NUM> from the rotating shaft <NUM> connected to the actuator <NUM>.

The rack gear <NUM> is disposed in the direction toward the engine room on the horizontal frame <NUM> disposed thereunder.

Then, the rack gear <NUM> engages the pinion gear <NUM> and the driven gear <NUM> and moves in the horizontal direction according to the power of the actuator <NUM> transmitted from the pinion gear <NUM>.

The rack gear <NUM> also rotates the driven gear <NUM> according to the rotation of the pinion gear <NUM> receiving power from the actuator <NUM>.

Accordingly, the rack gear <NUM> may operate the flap portion <NUM> by the link unit <NUM> connected to the rotation rod <NUM> by rotating the rotation rod <NUM> coupled to the driven gear <NUM>.

For this reason, the flap portion <NUM> may open or close the air inlet along the guide groove <NUM> of the horizontal frame <NUM> by the actuator <NUM>, the gear unit <NUM>, and the connection unit <NUM>.

The rack gear <NUM> includes a gear base portion <NUM>, a first gear <NUM>, a second gear <NUM>, and a third gear <NUM>.

The gear base portion <NUM> constitutes the body of the rack gear <NUM> and extends in the horizontal direction along the horizontal frame <NUM>.

The first gear <NUM> is formed on the gear base portion <NUM> and extends in a direction toward the driven gear <NUM> and pinion gear <NUM>.

The first gear <NUM> is formed at a position of the gear base portion <NUM> corresponding to the first connection unit 300_1 disposed on the horizontal end portion of the horizontal frame <NUM>.

Moreover, the first gear <NUM> is selectively engaged with the driven gear <NUM> of the first connection unit 300_1.

Specifically, when the rack gear <NUM> operates in the horizontal direction according to the operation of the actuator <NUM> as illustrated in <FIG>, the first gear <NUM> is engaged with the driven gear <NUM> of the first connection unit 300_1, or the driven gear <NUM> of the first connection unit 300_1 is disposed in a first space <NUM> to be described below.

That is, when the first gear <NUM> is engaged with the driven gear <NUM> of the first connection unit 300_1, the flap portions <NUM> of the first unit 230_1 connected to the first connection unit 300_1 is operated.

The second gear <NUM> is formed on the gear base portion <NUM> and extends in a direction toward the middle gear and the pinion gear <NUM>.

The second gear <NUM> is formed at a position of the gear base portion <NUM> spaced apart from the first gear <NUM>.

That is, the first space <NUM> is formed between the first gear <NUM> and the second gear <NUM> in the gear base portion <NUM>.

Moreover, the second gear <NUM> is selectively engaged with the driven gear <NUM> of the second connection unit 300_2.

Specifically, when the rack gear <NUM> operates in the horizontal direction according to the operation of the actuator <NUM> as illustrated in <FIG>, the second gear <NUM> is engaged with the driven gear <NUM> of the second connection unit 300_2, or the driven gear <NUM> of the second connection unit 300_2 is disposed in a second space <NUM> to be described below.

That is, the second gear <NUM> operates the flap portions <NUM> of the second unit 230_2 connected to the second connection unit 300_2 while being engaged with the driven gear <NUM> of the second connection unit 300_2.

The third gear <NUM> is formed in the gear base portion <NUM> and extends in the directions of the driven gear <NUM> and the pinion gear <NUM>, like the first gear <NUM> and the second gear <NUM>.

The third gear <NUM> is formed at a position of the gear base portion <NUM> spaced apart from a direction opposite to the first gear <NUM> spaced apart from the second gear <NUM>.

That is, the second space <NUM> is formed between the second gear <NUM> and the third gear <NUM> in the gear base portion <NUM>.

Moreover, the third gear <NUM> is selectively engaged with the driven gear <NUM> of the third connection unit 300_3.

Specifically, when the rack gear <NUM> operates in the horizontal direction according to the operation of the actuator <NUM> as illustrated in <FIG>, the third gear <NUM> is engaged with the driven gear <NUM> of the third connection unit 300_3, or the driven gear <NUM> of the third connection unit 300_3 is disposed at a position deviated from the third gear <NUM>.

That is, the third gear <NUM> operates the flap portions <NUM> of the third unit 230_3 connected to the third connection unit 300_3 while being engaged with the driven gear <NUM> of the third connection unit 300_3.

Meanwhile, the third gear <NUM> is formed at a position of the gear base portion <NUM> spaced apart from the second gear <NUM> by a distance greater than a distance between the first gear <NUM> and the second gear <NUM>.

That is, the space between the third gear <NUM> and the second gear <NUM>, that is, the second space <NUM>, is greater than the space between the first gear <NUM> and the second gear <NUM>, that is, the first space.

Accordingly, in the rack gear <NUM> of the present invention in which the distance between the first gear <NUM> and the second gear <NUM> and the distance between the second gear <NUM> and the third gear <NUM> are different from each other, when the rack gear <NUM> is operated in the horizontal direction by the actuator <NUM>, as illustrated in <FIG>, the first gear <NUM> and the driven gear <NUM> of the first connection unit 300_1 are engaged with each other first.

Then, as illustrated in <FIG>, the second gear <NUM> and the driven gear <NUM> of the second connection unit 300_2 are engaged with each other, and then, as illustrated in <FIG>, the third gear <NUM> and the driven gear <NUM> of the third connection unit 300_3 are engaged with each other.

Accordingly, as illustrated in <FIG>, the flap portions <NUM> of the first unit 230_1, the flap portions <NUM> of the second unit 230_2, and the flap portions <NUM> of the third unit 230_3 are sequentially operated according to the distances between the first gear <NUM> engaged with the driven gear <NUM> of the first connection unit 300_1, the second gear <NUM> engaged with the driven gear <NUM> of the second connection unit 300_2, and the third gear <NUM> engaged with the driven gear <NUM> of the third connection unit 300_3.

In addition, in the rack gear <NUM>, it is possible to adjust an opening/closing order and an opening/closing timing of the flap portions <NUM> of the first unit 230_1 to the third unit 230_3 by changing the design of the first gear <NUM> to the third gear <NUM> formed on the gear base portion <NUM> to adjust the distances therebetween.

For this reason, in the active air flap apparatus for a vehicle of the present invention, the air inlet of the grill is sequentially opened or closed, and thus, it is possible to improve the design sensibility of the grill.

In addition, by individually opening or closing the flap portions <NUM> of the first unit 230_1, the flap portions <NUM> of the second unit 230_2, and the flap portions <NUM> of the third unit 230_3, it is possible to remarkably reduce the air resistance introduced from the outside of the grill while the vehicle travels, and effectively open or close the flap portions <NUM> of the first unit 230_1 to the third unit 230_3 even when using an actuator <NUM> having a low performance.

The gear cover <NUM> is provided as a pair of gear covers, and the gear covers <NUM> are coupled to the rear surface of the horizontal frame <NUM> disposed on the upper side and the rear surface of the horizontal frame <NUM> disposed thereunder to seal the driven gear <NUM>, the pinion gear <NUM>, and the rack gear <NUM>.

The gear cover <NUM> prevents foreign substances from entering the driven gear <NUM>, the pinion gear <NUM>, and the rack gear <NUM>.

Accordingly, the gear cover <NUM> can effectively prevent the opening or closing of the flap portion <NUM> from malfunctioning due to inflow of foreign substances into the periphery of the rack gear <NUM> from the outside.

As such, the embodiments disclosed in this specification should be considered from an exemplary point of view for description rather than a limiting point of view.

According to the present invention, when the guide rod slides along the guide groove, the flap portion closes the air inlet while moving along the guide rod. Therefore, when the flap portion closes the air inlet, the front surface of the flap portion in the outward direction of the vehicle and the front surface of the grill can be integrated.

Moreover, the flap portions of the first unit, the flap portions of the second unit, and the flap portions of the third unit are sequentially operated according to the distances between the first gear engaged with the driven gear of the first connection unit, the second gear engaged with the driven gear of the second connection unit, and the third gear engaged with the driven gear of the third connection unit. Therefore, the air inlet of the grill is sequentially opened or closed, and thus, it is possible to improve design sensibility of the grill.

Claim 1:
An active air flap apparatus for a vehicle, comprising:
a frame (<NUM>) coupled to a rear surface of a grill in which an air inlet is disposed;
a plurality of flap portions (<NUM>) coupled to an inside of the frame (<NUM>) to open or close the air inlet and arranged in a vertical direction of the frame (<NUM>);
an actuator (<NUM>) coupled to an outside of the frame (<NUM>) to generate power;
a gear unit (<NUM>) operated by the power generated from the actuator (<NUM>); and
a connection unit (<NUM>) connecting the plurality of flap portions and the gear unit (<NUM>) to each other to operate the plurality of flap portions (<NUM>) according to an operation of the gear unit (<NUM>);
wherein the frame (<NUM>) includes:
two vertical frames (<NUM>) disposed to be spaced from each other by a distance; and
two horizontal frames (<NUM>) disposed on upper end portions and lower end portions of the vertical frames (<NUM>) to connect the two vertical frames (<NUM>) to each other; and
wherein the horizontal frames (<NUM>) include a guide groove (<NUM>), which guides an operation direction of the connection unit when the power is generated by the actuator (<NUM>);
a guide rod (<NUM>) which is inserted into the guide groove (<NUM>) and coupled to the plurality of flap portions (<NUM>) which are spaced from each other by a distance in a longitudinal direction;
characterized in that
the connection unit (<NUM>) includes:
a rotation rod (<NUM>) connected to the gear unit (<NUM>); and
a link unit (<NUM>), a number of which corresponds to that of the plurality of flap portions (<NUM>), connecting the rotation rod and the guide rod to each other.