Vehicle Air-Conditioning Insert With Networked Channels and Perforated Outlets
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Solution Overview
Problem
Existing air conditioning inserts for vehicles lack a simple and cost-effective structure for efficient air distribution and cooling, often requiring complex channel systems and multiple layers which increase manufacturing costs.
Innovation Solution
A network-like channel structure within a spacer material part, covered by a perforated cover layer, where channels connect at points forming holes from top to bottom, allowing controlled air release and mixing, thereby defining specific cooling zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex channel systems and multiple layers are used for air distribution, then air distribution efficiency is improved, but manufacturing cost and structural complexity increase
Solution Approach 1:
The air distribution function is segmented into two independent components: the spacer material part provides the channel network, and the cover layer provides the outlet openings. This segmentation allows each component to be manufactured separately using simple processes, then assembled together, reducing overall manufacturing complexity while maintaining effective air distribution.
Solution Approach 2:
The spacer material part and cover layer are combined to form an integrated air distribution system. The spacer material's channel structure merges with the cover layer's outlet openings to create a functional unit that achieves efficient air distribution without requiring complex internal channel systems within a single component.
2Reliability
If complex channel systems and multiple layers are used for air distribution, then air distribution efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The air distribution system is divided into separable components (spacer material part and cover layer) that can be manufactured using different, simpler processes. The spacer material can be produced by extrusion or molding, while the cover layer can be perforated separately, allowing for cost-effective manufacturing and assembly.
Solution Approach 2:
The design uses relatively simple, easily manufactured components that can be produced at low cost. The spacer material and cover layer are designed as straightforward structures that minimize material usage and manufacturing steps, making the overall system more cost-effective than complex integrated solutions.
3Reliability
If channels are connected to form network-like structure with intersection points, then air mixing and distribution are improved, but manufacturing precision requirements increase
Solution Approach 1:
The channel network and outlet openings are segmented into separate components. The spacer material part contains the channel network with intersection points where air mixing occurs, while the cover layer contains the outlet openings. This segmentation decouples the manufacturing precision requirements, allowing the channel intersections to be formed by simpler processes without requiring high-precision alignment between channels and outlets.
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
This design enables efficient air distribution and cooling by allowing air to be released through defined holes in the cover layer, improving cooling efficiency while maintaining a simple and cost-effective manufacturing process.
Implementation Method 1
The at least one spacer material part has a plurality of open regions extending from a top side to an opposite bottom side, which form a channel structure
Implementation Method 2
the at least one cover layer has at least one perforation, in particular a through-hole, in the region of connection or intersection points of the channels
Data Source
Figure 1
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AI summary
The invention relates to an insert for the air conditioning of a vehicle, comprising at least one spacer material section in which open areas extending from a top surface to an opposite bottom surface are formed, creating an air guidance structure. The at least one spacer material section is covered on the top surface and/or the bottom surface by at least one cover layer. The open areas of the air guidance structure comprise a plurality of channels which are interconnected, at least in partial regions of the at least one spacer material section, forming a network-like channel structure, flow areas, or flow zones. The at least one cover layer has at least one perforation in the area of connection or intersection points of the channels. A method for manufacturing an insert for the air conditioning of a vehicle is also described.