Vehicle Air Vent Flap Structure for Low-Leakage Sealing
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Solution Overview
Problem
Existing air vent systems for vehicles face challenges in reliable sealing due to complex production processes, high manufacturing costs, and issues with leakage and noise, particularly with two-component shut-off flaps and foam or felt seals.
Innovation Solution
An air vent system with a shut-off flap where both the flap body and sealing edge are made from the same material, with the sealing edge having lower rigidity than the flap body, achieved through geometry and manufacturing processes like injection molding, ensuring high stability and reliable sealing without the need for complex tooling or additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-component shut-off flap with softer sealing edge is used, then reliable sealing is achieved, but production cost and complexity increase
Solution Approach 1:
The patent applies local quality by creating a sealing edge with different mechanical properties (lower rigidity) than the flap body, both made from the same material. The sealing edge is designed with specific geometric features (curved cross-section, bellows-like structure) that provide localized flexibility and elasticity only where needed for sealing, while the flap body maintains high rigidity for structural stability. This resolves the contradiction by achieving reliable sealing through local structural optimization rather than using complex multi-material construction.
Solution Approach 2:
The patent changes physical parameters of the sealing edge by varying wall thickness and cross-sectional geometry. The sealing edge has a curved cross-section with multiple waves (expansion bellows shape) and reduced wall thickness compared to the flap body, which transforms the same material into a component with fundamentally different mechanical behavior - flexible and elastic where needed, rigid where required. This parameter-based differentiation resolves the sealing reliability vs. production complexity contradiction.
2Reliability
If foam or felt seals are used around the flap body, then sealing is achieved, but tool complexity and installation complexity increase
Solution Approach 1:
The patent merges the sealing function directly into the flap body structure by integrating the sealing edge as an integral part of the plastic component. Instead of using separate foam or felt seal components that require additional tooling and assembly steps, the sealing edge is molded as one piece with the flap body from the same material. This integration eliminates complex tooling requirements and simplifies installation while maintaining sealing reliability.
3Ease of manufacture
If the flap body comes directly into abutment with the sealing surface, then manufacturing is simplified, but gaps and leakage occur
Solution Approach 1:
The patent employs a flexible sealing edge with a curved cross-section resembling expansion bellows, made from the same plastic material as the rigid flap body. This flexible sealing edge can deform and adapt to the sealing surface, ensuring complete contact and eliminating gaps. The thin-walled, multi-waved structure of the sealing edge provides the necessary flexibility while maintaining structural integrity, resolving the contradiction between manufacturing simplicity and sealing reliability.
4Stability of the object's composition
If hard plastic flap body is used, then stability is achieved, but sealing flexibility is reduced
Solution Approach 1:
The patent segments the flap structure into two functional zones: a rigid flap body for stability and structural support, and a flexible sealing edge for adaptive sealing contact. Both are made from the same plastic material but are differentiated through geometric design - the flap body has sufficient wall thickness for rigidity, while the sealing edge has reduced wall thickness and a curved bellows-like cross-section for flexibility. This segmentation allows each zone to perform its specific function optimally.
Solution Approach 2:
The patent applies local quality by creating a sealing edge with different mechanical properties (lower rigidity) than the flap body, both made from the same material. The sealing edge is designed with specific geometric features (curved cross-section, bellows-like structure) that provide localized flexibility and elasticity only where needed for sealing, while the flap body maintains high rigidity for structural stability. This resolves the contradiction by achieving reliable sealing through local structural optimization rather than using complex multi-material construction.
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 reliable sealing, reduces manufacturing complexity and costs, and minimizes noise and leakage, while maintaining the stability of the flap body and the elasticity needed for effective sealing.
Implementation Method 1
the sealing edge of the shut-off flap is composed of the same material as the flap body and has a lower rigidity than the flap body
Data Source
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AI summary
Air vent (10) for a vehicle, comprising a housing (12) with an air duct (18) bounded by the housing (12), at least one shut-off flap (22) which is adjustable between a closed position and an open position within the air duct (18) and has a flap body (24) and a sealing edge (26) which at least partially surrounds the flap body (24) for butting against a sealing surface (20) of the housing (12) in the closed position, wherein the sealing edge (26) is composed of the same material as the flap body (24) and has a lower rigidity than the flap body (24).