Duct
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Solution Overview
Problem
Thin ducts molded from thermoplastic resin sheets face challenges in maintaining welding strength at parting lines, leading to potential cracking and peeling, especially when the sheets are thin and quickly cooled, which complicates attachment due to interference with other members.
Innovation Solution
The duct features projections on the inner surface sides of the parting lines and crashed sections on the outer surface sides, increasing the welding strength and facilitating attachment by enhancing the welding area without compromising the flow rate or rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the sheet thickness is reduced to lower cost and weight, then the duct weight decreases, but the welding strength of the parting line is lowered
Solution Approach 1:
The invention applies local quality by forming projections specifically at the parting line regions where welding occurs. These projections are localized structural modifications that concentrate material and strength exactly where needed (at the welded seams) without requiring the entire duct to be thicker, thus maintaining overall weight reduction while locally enhancing welding strength.
Solution Approach 2:
The invention transitions from a two-dimensional thin sheet to a three-dimensional structure by forming projections that extend from the sheet surface. This dimensional change creates additional welding area and volume at the parting lines, providing greater welding strength without significantly increasing the overall duct thickness or weight.
2Weight of stationary object
If the sheet thickness is reduced, then the cost decreases, but the welding area of the parting line is reduced
Solution Approach 1:
The projections create additional welding area by extending into the third dimension. Instead of relying solely on the limited surface area of a thin sheet, the projections provide volumetric welding area that increases the effective bonding zone at the parting lines, compensating for the reduced sheet thickness.
Solution Approach 2:
The projections are strategically formed only at the parting line regions, concentrating the additional welding area exactly where welding occurs. This localized approach increases welding area without adding unnecessary material throughout the entire duct structure.
3Strength
If a long rib is formed along the overall length of the crashed section to increase strength, then the welding strength increases, but the rib interferes with other members and complicates attachment
Solution Approach 1:
The projections are formed only at the parting line regions rather than as continuous long ribs along the entire duct length. This localized approach provides the necessary welding strength enhancement at the seams while leaving the rest of the duct surface smooth and free of interfering structures, thus maintaining ease of attachment for other members.
Solution Approach 2:
Instead of using a single continuous rib structure, the invention segments the reinforcement into discrete projections located at specific parting line positions. This segmentation provides strength where needed while minimizing interference with attachment operations in other regions.
Data Source
AI summary
A duct in which the welding strength of the parting lines is enhanced and which facilitates the attaching job is provided. The duct of the present embodying mode has a mean thickness of the entire duct of 1 mm or less, and includes projections on inner surface sides of the duct on the parting lines.