Vehicle Air Duct Locking Geometry to Prevent Over-Locking
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Solution Overview
Problem
Existing air duct systems require high assembly forces, leading to potential over-locking issues during manual assembly, which can result in unintentional disassembly.
Innovation Solution
An air duct system with polygonal cross-sections and a stop system comprising locking and counter-locking elements, along with a stop element and counter-stop element, to prevent over-locking by defining a defined end position for the locking connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high locking forces are used to ensure connection strength, then the disassembly resistance and connection reliability are improved, but the risk of over-locking during manual assembly increases, leading to unintentional disassembly
Solution Approach 1:
The stop system (stop element and counter-stop element) is designed to preemptively prevent over-locking by creating a mechanical barrier before the locking elements can engage excessively. The stop element protrudes into the engagement path, and the counter-stop element receives it, establishing a predefined engagement limit that prevents the harmful over-locking condition before it can occur during manual assembly
Solution Approach 2:
The stop system is pre-configured in the air duct components before assembly occurs. The stop element and counter-stop element are positioned in advance to automatically define the correct engagement position, eliminating the need for the assembler to judge or control the engagement force or distance, thus preventing over-locking through pre-established mechanical guidance
Data Source
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AI summary
An air duct system for a vehicle, comprising at least two air ducts, wherein the air ducts overlap in a common connecting region such that a first connecting section (4) of the first air duct is enclosed by a second connecting section (5) of the second air duct, and wherein the connecting sections (4, 5) have mutually corresponding polygonal cross-sections, and wherein the connecting sections (4, 5) are detachably connected to one another via at least one locking connection provided in the connecting region, wherein the locking connection is formed from a locking element (7) formed in the first connecting section (4) and a counter-locking element (8) formed in the second connecting section (5), wherein the connecting sections (4, 5) have mutually corresponding polygonal cross-sections, each with at least two corners (9b, 10a, 10b, 11a, 11b, 12a, 12b),wherein the locking element (7) and the counter-locking element (8) are each arranged on at least one of the respective, mutually abutting corners (9b, 10a, 10b) of the connecting sections (4, 5), wherein in the common connecting area, at least one stop system is additionally provided, comprising a stop element (14) formed in the first connecting section (4) and a counter-stop element (15) formed in the second connecting section (5), wherein the stop element (14) and the counter-stop element (15) are also arranged on at least one of the respective, mutually abutting corners (11a, 11b, 12a, 12b) of the connecting sections (4, 5), wherein the locking connection and the stop system are coordinated with one another such that, after the locking connection has engaged, the stop element (14) and the counter-stop element (15) predetermine a defined end position of the locking connection in order to prevent the locking connection from over-locking.