One-piece Air Guide with Flexible Ducts for Shock Absorption
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Solution Overview
Problem
Existing air guide systems for motor vehicles are costly to manufacture and labor-intensive to assemble due to the need for precise sealing of multiple connected parts, which complicates the assembly and increases production costs.
Innovation Solution
An air guide system featuring flexible upstream air inlet ducts made of elastomeric materials and a stiffer main downstream duct, designed to be assembled in a single piece using bi-injection techniques, allowing for deformation to absorb shocks and manufacturing tolerances, and incorporating additional air supply ducts for cooling other vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple air guide ducts are connected together to channel air, then air guidance function is improved, but sealing complexity and assembly labor increase significantly
Solution Approach 1:
The patent merges multiple separate air guide ducts into a single integrated air guide component. The upstream air inlet ducts are directly connected to the downstream main duct in a one-piece construction, eliminating the need for separate sealing operations between multiple ducts while maintaining the air guidance function.
Solution Approach 2:
The integrated air guide serves multiple functions simultaneously: it guides air from multiple upstream inlets to the downstream outlet, provides structural support, and eliminates sealing requirements. This multi-functionality reduces both sealing complexity and assembly labor.
2Adaptability or versatility
If multiple air guide ducts are assembled together, then air guidance capability is enhanced, but assembly labor and production costs increase
Solution Approach 1:
The patent combines multiple air guide ducts into a single molded component where upstream air inlet ducts are integrally connected to the downstream main duct. This eliminates the need for separate assembly operations and reduces production costs while maintaining enhanced air guidance capability.
3Strength
If rigid material is used for air guide ducts, then structural strength is improved, but shock absorption capability deteriorates
Solution Approach 1:
The patent applies different material properties to different regions of the air guide. The downstream main duct uses rigid reinforced polymer material for structural strength, while the upstream air inlet ducts use flexible elastomeric material for shock absorption. This local differentiation allows each region to optimize its function.
Solution Approach 2:
The patent uses composite material construction with the downstream main duct made of reinforced polymer material and upstream air inlet ducts made of elastomeric material. This composite approach combines the advantages of both rigid and flexible materials in a single integrated component.
4Manufacturing precision
If tight manufacturing tolerances are required for duct connections, then sealing quality is improved, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The patent eliminates the need for separate duct connections by integrating upstream air inlet ducts directly into the downstream main duct in a one-piece construction. This removes the requirement for tight manufacturing tolerances at connection interfaces, thereby reducing manufacturing costs while maintaining sealing quality.
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 reduces production costs, simplifies assembly, enhances sealing, and provides shock absorption, while facilitating the cooling of components like headlamps without additional air blowers, thereby improving the overall efficiency and durability of the air guide system.
Implementation Method 1
at least one upstream air intake duct exhibits a degree of flexibility, allowing the air guide to deform. This deformation capacity enables the air guide to absorb the energy of low-speed impacts
Implementation Method 2
at least one upstream air inlet duct is made of a flexible material, such as at least partially made of an elastomeric material
Implementation Method 3
the air guide, for example, is produced by bi-injection molding. Bi-injection allows two different materials to be injected into the same mold
Implementation Method 4
Behind this bumper beam are usually located the vehicle's heat exchangers, such as the one used for cabin air conditioning
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an air guide for a motor vehicle comprising at least one downstream main duct (7) intended to be positioned in front of a heat exchange device (5) of the motor vehicle (2) and at least one air inlet upstream duct (8, 9) intended to be connected to an air inlet (10, 11), the at least one air inlet upstream duct (8, 9) being connected to the downstream main duct (7) to guide the air from the air inlet (10, 11) toward the heat exchange device (5), characterized in that the air guide is made as a single piece.