Duct Mating Assembly With Transition Portion For Leak Prevention
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Solution Overview
Problem
The existing air duct assembly process in motor vehicles is inefficient and prone to air leaks due to manual alignment and assembly complexities, necessitating an improved method for efficient and leak-proof duct mating.
Innovation Solution
A duct mating assembly featuring connected side members with coupling portions, transition portions to prevent air leakage, and snap features for secure alignment and fastening, allowing for efficient coupling and secure retention of ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and assembly of ducts is used, then the ducts can be connected together, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The duct components are pre-formed with integrated coupling portions, alignment features, and sealing structures during manufacturing. This preliminary preparation eliminates the need for manual alignment operations during assembly, as the features automatically guide and secure the ducts when connected
Solution Approach 2:
The duct assembly system is designed to be self-aligning and self-securing through integrated coupling portions with alignment features that automatically position components correctly during assembly, eliminating the need for operator intervention for alignment and manipulation
2Manufacturing precision
If manual alignment of ducts is performed, then proper alignment can be achieved, but air leakage may still occur between ducts
Solution Approach 1:
The coupling portion integrates multiple functions into a single structure: alignment features for positioning, sealing surfaces for leak prevention, and fastening mechanisms for secure connection. This merging ensures that alignment precision and air leak prevention work together seamlessly
Solution Approach 2:
The coupling portion incorporates localized sealing surfaces and gasket structures at critical interfaces where air leakage is most likely to occur. These localized quality enhancements ensure reliable sealing without requiring perfect alignment across the entire duct structure
3Ease of manufacture
If multiple duct components are assembled manually, then the ventilation system can be constructed, but the manufacturing process becomes costly
Solution Approach 1:
The duct system is divided into modular components with standardized coupling portions. This segmentation allows for efficient manufacturing of individual components and rapid assembly through simple coupling operations, reducing both manufacturing complexity and labor costs
Solution Approach 2:
The coupling portion design is universal and can be applied to multiple duct components throughout the ventilation system. This multi-functionality allows the same coupling design to secure various duct types and sizes, simplifying the manufacturing process and reducing the need for specialized assembly procedures
Data Source
AI summary
A duct mating assembly includes first and second ducts having side surfaces connected along their edges to define an interior air space. A coupling portion is formed on one of the first or second ends of the ducts. The coupling portion of the first duct includes first and second sections joined by side sections. The first section of the first duct includes a fifth portion that extends to a sixth portion. A transition portion is positioned between the fifth and sixth portions. The transition portion steps downward and extends forward and then steps back up relative to the fifth portion for preventing air leakage between the first and second ducts. The second section of the first duct includes a first snap feature formed thereon and the fourth section of the second duct including a second snap feature formed thereon, the first and second snap features are operative to connect the second and fourth sections of the first and second ducts.