Ram air flap system

Abstract

An assembly for increasing air flow to a vehicle cooling system includes a portion of a cooling fan shroud, the portion having a face defining an opening therethrough, and a plurality of support members extending from the face. A flap includes a plurality of apertures proximal to an edge. Each aperture of the plurality of apertures is formed to receive one of the plurality of support members for coupling the flap thereto. A clearance fit formed between the apertures and the support members permits movement of the flap from a first position generally parallel to the face to a second position in response to a flow of air.

1 . An assembly for increasing air flow to a vehicle cooling system, the assembly comprising:
 a portion of a cooling fan shroud, the portion having
 a face defining an opening therethrough, and 
 a plurality of support members extending from the face; and 
   a flap including a plurality of apertures proximal to an edge, each aperture of the plurality of apertures formed to receive one of the plurality of support members for coupling the flap thereto, wherein a clearance fit formed between the apertures and the support members permits movement of the flap from a first position generally parallel to the face to a second position in response to a flow of air.   
     
     
         2 . The assembly of  claim 1 , wherein the cooling fan shroud includes a recess integrally formed in the face adjacent the plurality of support members, wherein the recess accommodates movement of the edge as the flap moves from the first position to the second position. 
     
     
         3 . The apparatus of  claim 1 , wherein the shroud portion further includes at least one guide member adjacent to the recess and extending from the face, the guide member cooperative with at least one support of the plurality of supports to limit movement of the flap to the second position. 
     
     
         4 . The apparatus of  claim 3 , wherein the second position is approximately 60° from the first position. 
     
     
         5 . The apparatus of  claim 1 , wherein the flap blocks the opening in the first position. 
     
     
         6 . The apparatus of  claim 1 , wherein the flap is punched from one of an extruded and a rolled film. 
     
     
         7 . The apparatus of  claim 1 , wherein the flap is cut from one of an extruded and a rolled film. 
     
     
         8 . The apparatus of  claim 1 , wherein the flap is constructed of a thermoplastic, elastomer, or metal. 
     
     
         9 . The apparatus of  claim 1 , wherein the opening is a first opening and wherein the face further defines a second opening therethrough, the second opening separated from the first opening by a support member. 
     
     
         10 . The apparatus of  claim 1 , wherein the flap further includes a reinforcement member generally orthogonal to the edge. 
     
     
         11 . The apparatus of  claim 1 , wherein the recess is arcuate in cross-section. 
     
     
         12 . The apparatus of  claim 1 , wherein the shroud portion further includes opposing pivot supports projecting across a portion of the opening and defining a pivot axis operable to support a rotatable flap. 
     
     
         13 . The method of  claim 1 , wherein the thickness of the flap is between 0.05 to 0.8 mm. 
     
     
         14 . A cooling fan shroud for a vehicle, the cooling fan shroud comprising:
 a cooling fan shroud face having
 a primary opening therethrough for a cooling fan, 
 a plurality of secondary openings therethrough, and 
 a plurality of support members extending from the face adjacent each secondary opening; and 
   a flap including a plurality of apertures proximal to an edge, each aperture of the plurality of apertures formed to receive one of the plurality of support members for coupling the flap thereto, wherein a clearance fit formed between the apertures and the support members permits movement of the flap from a first position generally parallel to the shroud face to a second position in response to a flow of air.   
     
     
         15 . A method of producing a cooling fan shroud, the method comprising:
 injection molding a shroud portion having
 a face defining an opening therethrough, 
 a plurality of support members extending from the face, and 
 a guide member adjacent the opening and extending from the face; and 
   coupling a flap to the plurality of support members, wherein the coupling includes flexing the flap to engage the support members of the plurality of support members.   
     
     
         16 . The method of  claim 15 , wherein coupling a flap to the plurality of support members means coupling a flap having a plurality of apertures along a first edge, the apertures spaced to each receive one of the plurality of support members. 
     
     
         17 . The method of  claim 15  wherein coupling a flap to the plurality of support members means coupling a flap having a thickness of between 0.05 to 0.8 mm. 
     
     
         18 . The method of  claim 16 , wherein coupling the flap to the plurality of support members includes elastically deforming the flap to position each of the plurality of apertures over each of the plurality of support members. 
     
     
         19 . The method of  claim 16 , wherein coupling the flap to the plurality of support members includes elastically deforming the flap between the guide member and the plurality of support members such that an end of each support member of the plurality of support members extends through a respective aperture of the flap. 
     
     
         20 . The method of  claim 18 , further including guiding the flap along the guide member into a recess. 
     
     
         21 . The method of  claim 15 , wherein injection molding the shroud portion means injection molding the guide member to be disposed cooperatively with at least one support of the plurality of supports to limit operable movement of the flap. 
     
     
         22 . An assembly for increasing air flow to a vehicle cooling system, the assembly comprising:
 a portion of a cooling fan shroud, the portion having
 a face defining an opening therethrough, and 
 a plurality of support members extending from the face; and 
   a flap including a plurality of apertures proximal to an edge, each aperture of the plurality of apertures formed to receive one of the plurality of support members for coupling the flap thereto, wherein a clearance fit formed between the apertures and the support members permits movement of the flap from a first position generally parallel to the face to a second position in response to a flow of air, and wherein the flap is retained on the shroud portion at least partially by one or more elastic members attached to the shroud portion or formed as an integral part of the shroud portion, the elastic members being flexed during engagement of the apertures with the support members.