Homogeneous Plastic Air Flap Assembly Labyrinth Seal
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Solution Overview
Problem
Air flap assemblies in vehicle heating, ventilating, and air conditioning systems with rigid and soft materials require complex production methods, leading to high production costs and inefficiencies.
Innovation Solution
A homogenous plastic air flap assembly with a sealing mechanism featuring an outer groove and protruding structure, forming a labyrinth seal that eliminates the need for deformation and allows for a simpler, more cost-effective production process, along with optional radially extending grooves and protruding structures for enhanced sealing and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid and soft materials are used for air flap assembly, then sealing function is improved, but production complexity increases and production costs rise
Solution Approach 1:
The air flap assembly is made from a single homogeneous plastic material throughout, eliminating the need for multiple materials (rigid and soft) that were previously required. This homogenization maintains adequate sealing function while dramatically simplifying production processes and reducing costs.
Solution Approach 2:
The invention combines the functions of rigid structural components and soft sealing elements into a single integrated plastic component. The air flap assembly integrates both structural support and sealing functions in one homogeneous material, eliminating the need for separate soft material components and complex assembly processes.
2Reliability
If rigid and soft materials are used for air flap assembly, then sealing function is improved, but production costs increase
Solution Approach 1:
The air flap assembly is made from a single homogeneous plastic material throughout, eliminating the need for multiple materials (rigid and soft) that were previously required. This homogenization maintains adequate sealing function while dramatically simplifying production processes and reducing costs.
Solution Approach 2:
The invention uses a cost-effective homogeneous plastic material that can be manufactured through simple injection molding processes, replacing expensive multi-material construction. The simplified design allows for high-volume production at lower cost while maintaining functional requirements.
3Reliability
If sealing material deformation is required, then seal quality is improved, but structural integrity is compromised
Solution Approach 1:
The air flap assembly is made from a single homogeneous plastic material throughout, eliminating the need for multiple materials (rigid and soft) that were previously required. This homogenization maintains adequate sealing function while dramatically simplifying production processes and reducing costs.
Solution Approach 2:
The invention incorporates resilient movement capability into the homogeneous plastic structure through strategically placed weakening areas. These areas allow localized flexible deformation at sealing interfaces while maintaining overall structural rigidity, enabling the single material to adapt dynamically to sealing requirements without compromising strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reliable seal with reduced production costs and noise, enabling smooth operation and efficient airflow management while maintaining structural integrity.
Implementation Method 1
the protruding structure rests in the groove in the closed position of the air flap forming a seal of the air opening. The protruding structure and the groove form a kind of labyrinth seal which allows good sealing function of the sealing mechanism.
Implementation Method 2
the vane of the air flap has at least one weakening area allowing resilient movement of the protruding structures in the closed position. the air flap may be deformed in order for the protruding structures to come in optimal sealing contact with the seat of the air opening.
Data Source
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AI summary
The present invention relates to an air flap assembly (12) of a ventilation system of a vehicle heating, ventilating and/or air conditioning system (10), comprising: - an air flap (20) having a rotation axis (22) and at least one vane (24) extending in a sideward direction from the rotation axis (22), the vane (24) having an outer edge (26) along a free end of the air flap (20) and two side edges (28); and - a casing (14) having an air opening (16) with a rim forming a seat (18) for the air flap (20), - the air flap (20) having a closed position in which the air flap (20) rests against the seat (18) of the air opening (16) and seals the air opening (16), and an open position in which the air flap (20) is swiveled about the rotation axis (22) relative to the closed position. The air flap assembly (12) has a sealing mechanism (30) comprising : - an outer groove (32) and an outer protruding structure (34) one of which being provided at the seat (18) of the air opening (16) and - the other one of which being provided on the vane (24) of the air flap (20) in the region of the outer edge (26) of the air flap (20), wherein the protruding structure (34) rests in the outer groove (32) in the closed position of the air flap (20) forming a seal of the air opening (16).