Lightweight composite material automobile air duct

Abstract

The utility model discloses a lightweight composite material automobile air duct which comprises an air duct body composed of an inner layer, a middle layer and an outer layer, the inner layer is made of high-temperature-resistant flexible materials, the outer layer is made of high-strength fiber reinforced composite materials, and the middle layer is made of honeycomb-shaped lightweight core materials. The device further comprises a supporting framework, reinforcing ribs, a flange plate, a butt joint part and a flow guide device. Through the design of the three-layer composite structure and optimization of the honeycomb core material, the weight is remarkably reduced while the strength is guaranteed, the structural stability is improved through the supporting framework and the reinforcing ribs, airflow distribution is optimized through the flow guiding device, the connection sealing performance and firmness are guaranteed through the flange plate and the butt joint part, and the durability is enhanced through the outer protection layer. While light weight is achieved, strength, sealing performance and durability are considered, and the requirement of the modern automobile industry for a high-performance air pipe is met.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts and composite material application technology, and in particular to a lightweight composite material automotive air duct. Background Technology

[0002] Automotive air ducts are a crucial component of vehicle air conditioning systems, primarily used to guide airflow for temperature regulation and air circulation within the vehicle. With the rapid development of the automotive industry, the performance requirements for air ducts have gradually increased, including strength, heat resistance, sealing, and lightweighting. Especially in the field of new energy vehicles, reducing component weight has become a key means of improving driving range and reducing energy consumption. Traditional automotive air ducts are mostly made of metal or single-material plastics, which, while meeting basic functional requirements, suffer from problems such as significant weight and high processing complexity.

[0003] In recent years, composite materials have been widely used in the automotive parts industry due to their excellent mechanical properties and designability. For example, some existing technologies attempt to replace traditional materials with fiber-reinforced composite materials to achieve the goal of lightweighting air ducts. However, these technical solutions still face some limitations in practical applications. For instance, the manufacturing process of some composite air ducts is relatively complex, leading to increased costs; at the same time, some design solutions, while meeting the requirements for lightweighting, fail to fully consider the structural strength and durability requirements of the air duct.

[0004] During their research, the inventors discovered that there is currently no automotive duct solution that can comprehensively balance lightweighting, strength, and manufacturing costs. Therefore, there is an urgent need for a new type of lightweight composite material automotive duct to overcome these shortcomings and meet the demands of the modern automotive industry. Utility Model Content

[0005] The purpose of this utility model is to provide a lightweight composite material automotive air duct that solves the problems mentioned in the background art.

[0006] This invention is achieved through a lightweight composite material automotive air duct.

[0007] The duct body comprises an inner layer, a middle layer, and an outer layer, which are fixedly connected by an adhesive, with the middle layer embedded between the inner and outer layers. The inner layer is made of a high-temperature resistant flexible material, the outer layer is made of a high-strength fiber-reinforced composite material, and the middle layer is a lightweight core material with a honeycomb structure and a porosity of 30%-50%. One end of the duct body has a flange with several positioning grooves on its outer wall, each groove containing an elastic sealing ring. The other end of the duct body has a connecting portion with an annular protrusion on its outer wall. A locking sleeve is fitted around the annular protrusion, and the inner wall of the locking sleeve has a groove that matches the annular protrusion. The duct body also includes:

[0008] The support frame is embedded in the middle layer and consists of several arc-shaped ribs. The arc-shaped ribs are evenly distributed along the axial direction of the duct body and adjacent arc-shaped ribs are fixedly connected by connecting pieces. The reinforcing ribs are set on the outer wall of the outer layer. The reinforcing ribs extend along the axial direction of the duct body and have a trapezoidal cross section.

[0009] The flange has several clips on its inner wall, which are connected to the end of the duct body by threads. The inner side of the clips is provided with elastic gaskets.

[0010] Optionally, the outer wall of the duct body is provided with several heat dissipation holes, and a filter screen is provided on the inner side of the heat dissipation holes. The filter screen is fixed to the inner wall of the duct body by a slot, and the slot has a T-shaped cross section.

[0011] Optionally, it also includes a flow guiding device disposed inside the duct body. The flow guiding device includes: a flow guiding plate disposed on the inner wall of the inner layer of the duct body, and the surface of the flow guiding plate is provided with a plurality of flow guiding grooves, the cross section of the flow guiding grooves being arc-shaped.

[0012] The flow divider is located in the middle of the guide plate. Both ends of the flow divider are fixedly connected to the inner wall of the duct body. The surface of the flow divider is provided with several through holes with a diameter of 2mm-5mm.

[0013] The guide plate and the flow divider are connected by a hinge, with the two ends of the hinge embedded in the preset slots of the guide plate and the flow divider, respectively.

[0014] Optionally, the inner wall of the locking sleeve is provided with a plurality of anti-slip protrusions, the cross-section of the anti-slip protrusions is semi-circular, and the anti-slip protrusions are evenly distributed along the circumference of the locking sleeve.

[0015] Optionally, the outer side wall of the flange is provided with a plurality of mounting holes, the inner side wall of the mounting holes is provided with threads, and the depth of the mounting holes is 1 / 3 to 1 / 2 of the flange thickness.

[0016] Optionally, it also includes a protective layer disposed on the outside of the duct body, the protective layer consisting of a wear-resistant coating and an anti-corrosion coating, the wear-resistant coating being coated on the outer side wall of the outer layer, the anti-corrosion coating being coated on the outside of the wear-resistant coating, and the thickness of the anti-corrosion coating being 0.1mm-0.3mm.

[0017] Optionally, the cross-section of the arc-shaped rib is elliptical, and a plurality of reinforcing columns are provided on the inner side of the arc-shaped rib. The cross-section of the reinforcing columns is circular, and the diameter of the reinforcing columns is 1 / 4 to 1 / 3 of the thickness of the arc-shaped rib.

[0018] Optionally, the depth of the guide groove is 1 / 5 to 1 / 4 of the thickness of the guide plate, and the width of the guide groove is 1 / 3 to 1 / 2 of the width of the guide plate.

[0019] Optionally, the outer wall of the locking sleeve is provided with a plurality of operating blocks, the surface of which is provided with anti-slip texture, the depth of which is 0.2mm-0.5mm.

[0020] Optionally, the cross-section of the elastic sealing ring is O-shaped, the material of the elastic sealing ring is silicone, and the hardness of the elastic sealing ring is Shore hardness 30A-50A.

[0021] The technical advantages of this invention are as follows: This invention employs a three-layer composite structure design, using a high-temperature resistant flexible material as the inner layer, a high-strength fiber-reinforced composite material as the outer layer, and embedding a lightweight honeycomb core material in between. This significantly reduces weight while maintaining the strength of the duct. The porosity of the honeycomb structure is optimized, reducing overall weight while retaining good compressive strength. The introduction of the supporting frame further enhances the structural stability of the duct, and the combination of arc-shaped ribs and connecting pieces effectively disperses stress, preventing deformation or damage caused by excessive localized stress.

[0022] The design of the flange and mating section makes the connection between ducts more convenient and reliable. The positioning groove on the flange cooperates with the elastic sealing ring to improve the sealing performance of the connection, while the annular protrusion on the mating section cooperates with the groove of the locking sleeve to ensure the firmness of the connection. The anti-slip protrusions on the inner wall of the locking sleeve further increase friction and prevent loosening.

[0023] The airflow guiding device optimizes the airflow distribution inside the duct. The arc-shaped guide grooves on the guide plate guide the airflow smoothly, reducing turbulence; the through holes on the flow divider act as a diversion device, preventing airflow from concentrating and impacting a particular area. The guide plate and flow divider are connected by hinges, facilitating disassembly and maintenance.

[0024] The outer reinforcing ribs and external protective layer further enhance the durability and protective performance of the duct. The trapezoidal cross-section design of the reinforcing ribs improves bending resistance without adding excessive weight, while the combination of wear-resistant and anti-corrosion coatings extends the service life of the duct, making it particularly suitable for use in harsh environments.

[0025] In summary, this utility model, through multi-level structural design and functional optimization, achieves lightweighting while also considering strength, sealing, and durability, thus meeting the demands of the modern automotive industry for high-performance air ducts. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0027] Figure 2 This is a cross-sectional view of the main body of the air duct of this utility model;

[0028] Figure 3 This is a side view of the present invention.

[0029] The attached diagram is labeled as follows: 1. Duct body; 2. Inner layer; 3. Outer layer; 4. Middle layer; 5. Flange; 6. Connecting part; 7. Support frame; 8. Arc-shaped rib; 9. Connecting piece; 10. Reinforcing column; 11. Guide plate; 12. Diverter plate; 13. Guide groove; 14. Through hole; 15. Hinge. Detailed Implementation

[0030] This utility model provides a lightweight composite material automotive air duct, the specific implementation of which is as follows (in conjunction with the appendix). Figure 1 To be continued Figure 3 Please provide a detailed explanation. Figure 1 This is a schematic diagram of the overall structure of the present utility model, showing the layered structure of the duct body 1 and the design of the flange 5 and the docking part 6; Figure 2 The enlarged view of the supporting frame 7 and the middle layer 4 shows the distribution of the arc-shaped ribs 8, connecting pieces 9 and reinforcing columns 10. Figure 3 This is a schematic diagram of the flow guiding device, including the flow guide plate 11, the flow divider 12 and the connection method of its hinge 15, and the positions of the flow guide groove 13 and the through hole 14 are marked.

[0031] The duct body 1 consists of an inner layer 2, a middle layer 4, and an outer layer 3. The inner layer 2 and the outer layer 3 are fixedly connected by an adhesive, and the middle layer 4 is embedded between the inner layer 2 and the outer layer 3. The inner layer 2 is made of a high-temperature resistant flexible material, such as polytetrafluoroethylene or silicone rubber. This material has good heat resistance and flexibility, making it suitable for high-temperature airflow environments. The outer layer 3 is made of a high-strength fiber-reinforced composite material, such as carbon fiber composite material or glass fiber composite material. This material has high mechanical strength and impact resistance. The middle layer 4 is a lightweight core material with a honeycomb structure. The porosity of the honeycomb structure is 30%-50%, and the selection of the porosity takes into account the balance between weight reduction and compressive strength. The core material of the honeycomb structure can be aluminum honeycomb or aramid paper honeycomb, which can provide sufficient rigidity while ensuring lightweight design. The combined design of the inner layer 2, middle layer 4, and outer layer 3 achieves a balance between lightweight and high strength in the duct body 1 as a whole.

[0032] One end of the duct body 1 is equipped with a flange 5. Several positioning grooves are formed on the outer wall of the flange 5, and elastic sealing rings are embedded within these grooves. Several clips are provided on the inner wall of the flange 5, and these clips are threaded to the end of the duct body 1. An elastic gasket is provided on the inner side of each clip. Several mounting holes are also provided on the outer wall of the flange 5, and the inner wall of each mounting hole is threaded. The depth of the mounting holes is 1 / 3 to 1 / 2 of the thickness of the flange 5. The flange 5 is designed for connection with other components. The cooperation between the positioning grooves and the elastic sealing rings ensures the sealing performance at the connection, preventing gas leakage. The clips and elastic gaskets further enhance the connection stability between the flange 5 and the duct body 1.

[0033] The other end of the duct body 1 is provided with a connecting part 6. An annular protrusion is provided on the outer wall of the connecting part 6, and a locking sleeve is fitted around the outer side of the annular protrusion. The inner wall of the locking sleeve has a groove that matches the annular protrusion. Several anti-slip protrusions are also provided on the inner wall of the locking sleeve. The anti-slip protrusions have a semi-circular cross-section and are evenly distributed along the circumference of the locking sleeve. Several operating blocks are provided on the outer wall of the locking sleeve. The surface of the operating blocks has anti-slip textures with a depth of 0.2mm-0.5mm. The connecting part 6 is designed to enable quick connection of the duct body 1 with other ducts or equipment. The annular protrusion and the groove of the locking sleeve ensure a secure connection, and the anti-slip protrusions increase friction to prevent loosening. The operating blocks facilitate the application of force by the user during installation or disassembly.

[0034] The support frame 7 is embedded inside the middle layer 4. The support frame 7 consists of several arc-shaped ribs 8, which are evenly distributed along the axial direction of the duct body 1. Adjacent arc-shaped ribs 8 are fixedly connected by connecting pieces 9. The cross-section of the arc-shaped ribs 8 is elliptical, and several reinforcing columns 10 are provided on the inner side of the arc-shaped ribs 8. The reinforcing columns 10 have a circular cross-section, and their diameter is 1 / 4 to 1 / 3 of the thickness of the arc-shaped ribs 8. The design of the support frame 7 enhances the structural stability of the duct body 1. The combination of the arc-shaped ribs 8 and the connecting pieces 9 effectively disperses stress, preventing deformation or damage caused by excessive local stress. The reinforcing columns 10 further improve the load-bearing capacity of the arc-shaped ribs 8.

[0035] The reinforcing ribs are installed on the outer side wall of the outer layer 3, extending axially along the main body of the duct 1, and have a trapezoidal cross-section. The design of the reinforcing ribs can improve the bending resistance of the main body of the duct 1 without adding too much weight, and the trapezoidal cross-section design gives the reinforcing ribs better resistance to deformation when subjected to external forces.

[0036] The outer wall of the duct body 1 is provided with several heat dissipation holes, and a filter screen is provided on the inner side of the heat dissipation holes. The filter screen is fixed to the inner wall of the duct body 1 by a T-shaped groove. The heat dissipation holes are designed to exhaust heat from inside the duct, while the filter screen prevents external impurities from entering the duct. The T-shaped groove design ensures the stable installation of the filter screen.

[0037] A flow guiding device is installed inside the duct body 1, and includes a flow guiding plate 11 and a flow splitter 12. The flow guiding plate 11 is installed on the inner wall of the inner layer 2 of the duct body 1. The surface of the flow guiding plate 11 is provided with several flow guiding grooves 13. The cross-section of the flow guiding grooves 13 is arc-shaped. The depth of the flow guiding grooves 13 is 1 / 5 to 1 / 4 of the thickness of the flow guiding plate 11, and the width of the flow guiding grooves 13 is 1 / 3 to 1 / 2 of the width of the flow guiding plate 11. The flow splitter 12 is located in the middle of the flow guiding plate 11. Both ends of the flow splitter 12 are fixedly connected to the inner wall of the duct body 1. The surface of the flow splitter 12 is provided with several through holes 14, and the diameter of the through holes 14 is 2mm to 5mm. The flow guiding plate 11 and the flow splitter 12 are connected by a hinge 15. Both ends of the hinge 15 are respectively embedded in the preset grooves of the flow guiding plate 11 and the flow splitter 12. The design of the airflow guiding device optimizes the airflow distribution inside the duct. The airflow guide groove 13 guides the airflow to flow smoothly and reduces the occurrence of turbulence. The through holes 14 on the flow divider 12 serve to divert the airflow and prevent the airflow from concentrating and impacting a certain area. The hinge 15 facilitates the disassembly and maintenance of the airflow guide plate 11 and the flow divider 12.

[0038] The duct body 1 is also equipped with a protective layer on the outside, which consists of a wear-resistant coating and an anti-corrosion coating. The wear-resistant coating is applied to the outer wall of the outer layer 3, and the anti-corrosion coating is applied to the outside of the wear-resistant coating. The thickness of the anti-corrosion coating is 0.1mm-0.3mm. The design of the protective layer extends the service life of the duct body 1, and is especially suitable for use in harsh environments.

[0039] The elastic sealing ring has an O-shaped cross-section and is made of silicone. Its hardness is Shore A 30A-50A. The design of the elastic sealing ring ensures a tight seal when flange 5 is connected to external components, and the choice of silicone material balances elasticity and durability.

[0040] The connection, position, and cooperation relationships among the aforementioned components together constitute the specific implementation of this utility model. The material selection, structural design, and functional implementation of each component have been optimized to meet the requirements of lightweight, high strength, and high durability.

[0041] To enable those skilled in the art to fully understand and implement this utility model, the following supplementary explanation of the specific implementation principle of this utility model is provided in conjunction with a specific application scenario.

[0042] In practical applications, suppose this lightweight composite material automotive air duct is installed in the air conditioning system of a new energy vehicle to guide airflow and achieve in-vehicle temperature regulation and air circulation. The specific steps are as follows:

[0043] First, during the installation of the duct body 1, the flange 5 is fixedly connected to the connection port of the vehicle's air conditioning system through the mounting holes on its outer wall. The threaded design on the inner wall of the mounting holes ensures that the flange 5 can be firmly fitted with external components, while the elastic sealing ring in the positioning groove plays a crucial role. When the flange 5 is pressed against the external components, the elastic sealing ring deforms under force, filling any possible tiny gaps, thereby effectively preventing gas leakage. At the same time, the design of the snap-fit ​​connection to the end of the duct body 1 via threads further enhances the stability between the flange 5 and the duct body 1, preventing loosening due to vibration or impact.

[0044] Secondly, the design of the docking part 6 allows the duct body 1 to be quickly connected to other ducts or equipment. During installation, the locking sleeve is fitted onto the annular protrusion of the docking part 6, and the groove on the inner wall of the locking sleeve fits tightly against the annular protrusion, forming a strong mechanical connection. The anti-slip protrusion on the inner wall of the locking sleeve increases friction, further improving the reliability of the connection. The anti-slip texture on the surface of the operating block facilitates the operator in applying force, ensuring that the locking sleeve is accurately positioned. This design not only simplifies the installation process but also improves the efficiency and safety of the connection.

[0045] Next, the supporting frame 7 plays a crucial structural support role inside the duct body 1. The arc-shaped ribs 8 are evenly distributed along the axial direction of the duct body 1 and are fixedly connected by connecting pieces 9, forming a stable frame structure. When the duct is subjected to external pressure or internal airflow impact, the arc-shaped ribs 8 can effectively disperse stress, preventing deformation in localized areas due to excessive force. The reinforcing columns 10 further enhance the load-bearing capacity of the arc-shaped ribs 8, enabling them to meet high strength requirements while maintaining lightweight design. Furthermore, the reinforcing ribs on the outer wall of the outer layer 3, through their trapezoidal cross-section design, significantly improve the bending resistance of the duct body 1 without significantly increasing weight, thus ensuring the stability of the duct under complex operating conditions.

[0046] Subsequently, the operation of the flow guiding device optimizes the airflow distribution inside the duct. When the airflow enters the duct body 1, the arc-shaped guide grooves 13 on the guide plate 11 guide the airflow smoothly along a predetermined path, reducing turbulence. The through holes 14 on the diverter 12 act as a diversion mechanism, preventing airflow from concentrating and impacting a specific area, thereby reducing the risk of damage caused by excessive local pressure. The hinge 15 allows for flexible disassembly of the guide plate 11 and the diverter 12, facilitating future maintenance and replacement.

[0047] Finally, the protective layer design extends the service life of the duct body 1. The wear-resistant coating is applied directly to the outer wall of the outer layer 3, resisting damage from external friction; the anti-corrosion coating further provides a protective barrier, preventing the duct from failing due to corrosion in harsh environments. The ventilation holes allow heat to dissipate from the duct in a timely manner, while the T-shaped slotted filter effectively blocks external impurities from entering the duct, ensuring a clean internal environment.

[0048] As can be seen from the above steps, this utility model achieves a balance of lightweight, high strength, and high durability in practical applications through multi-level structural design and functional optimization, thus meeting the needs of the modern automotive industry for high-performance air ducts.

[0049] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A lightweight composite material automotive air duct, comprising an air duct body (1), characterized in that, The duct body (1) is composed of an inner layer (2), a middle layer (4) and an outer layer (3). The inner layer (2) and the outer layer (3) are fixedly connected by an adhesive. The middle layer (4) is embedded between the inner layer (2) and the outer layer (3). The inner layer (2) is made of polytetrafluoroethylene or silicone rubber. The outer layer (3) is made of carbon fiber composite material or glass fiber composite material. The middle layer (4) is a lightweight core material with a honeycomb structure. The porosity of the honeycomb structure is 30% to 50%. One end of the duct body (1) is provided with a flange (5). Several positioning grooves are opened on the outer side wall of the flange (5). An elastic sealing ring is embedded in the positioning groove. The other end of the duct body (1) is provided with a connecting part (6). An annular protrusion is provided on the outer side wall of the connecting part (6). A locking sleeve is fitted on the outer side of the annular protrusion. A groove matching the annular protrusion is provided on the inner wall of the locking sleeve.

2. The lightweight composite material automotive air duct as described in claim 1, characterized in that, It also includes a support frame (7), which is embedded in the middle layer (4). The support frame (7) is composed of several arc-shaped ribs (8). The arc-shaped ribs (8) are evenly distributed along the axial direction of the air duct body (1). Adjacent arc-shaped ribs (8) are fixedly connected by connecting pieces (9). The cross-section of the arc-shaped ribs (8) is elliptical. Several reinforcing columns (10) are provided on the inner side of the arc-shaped ribs (8). The cross-section of the reinforcing columns (10) is circular. The diameter of the reinforcing columns (10) is 1 / 4 to 1 / 3 of the thickness of the arc-shaped ribs (8).

3. The lightweight composite material automotive air duct as described in claim 1, characterized in that, It also includes reinforcing ribs set on the outer side wall of the outer layer (3), the reinforcing ribs extending along the axial direction of the air duct body (1), and the cross section of the reinforcing ribs is trapezoidal.

4. The lightweight composite material automotive air duct as described in claim 1, characterized in that, It also includes a flow guiding device disposed inside the duct body (1). The flow guiding device includes a flow guiding plate (11) and a flow splitter (12). The flow guiding plate (11) is disposed on the inner wall of the inner layer (2) of the duct body (1). The surface of the flow guiding plate (11) is provided with a plurality of flow guiding grooves (13). The cross-section of the flow guiding grooves (13) is arc-shaped. The depth of the flow guiding grooves (13) is 1 / 5 to 1 / 4 of the thickness of the flow guiding plate (11). The width of the flow guiding grooves (13) is 1 / 4 of the width of the flow guiding plate (11). 1 / 3 to 1 / 2; the diverter (12) is located in the middle of the guide plate (11), and the two ends of the diverter (12) are fixedly connected to the inner wall of the duct body (1) respectively. The surface of the diverter (12) is provided with several through holes (14), and the diameter of the through holes (14) is 2 mm to 5 mm; the guide plate (11) and the diverter (12) are connected by a hinge (15), and the two ends of the hinge (15) are respectively embedded in the preset grooves of the guide plate (11) and the diverter (12).

5. The lightweight composite material automotive air duct as described in claim 1, characterized in that, The inner wall of the locking sleeve is provided with a number of anti-slip protrusions, the cross-section of which is semi-circular. The anti-slip protrusions are evenly distributed along the circumference of the locking sleeve. The outer wall of the locking sleeve is provided with a number of operating blocks, the surface of which is provided with anti-slip texture, the depth of which is 0.2 mm to 0.5 mm.

6. The lightweight composite material automotive air duct as described in claim 1, characterized in that, The outer side wall of the flange (5) is provided with several mounting holes, and the inner side wall of the mounting holes is provided with threads. The depth of the mounting holes is 1 / 3 to 1 / 2 of the thickness of the flange (5).

7. The lightweight composite material automotive air duct as described in claim 1, characterized in that, It also includes a protective layer disposed on the outside of the duct body (1), the protective layer consisting of a wear-resistant coating and an anti-corrosion coating, the wear-resistant coating being coated on the outer side wall of the outer layer (3), the anti-corrosion coating being coated on the outside of the wear-resistant coating, and the thickness of the anti-corrosion coating being 0.1 mm to 0.3 mm.

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