Flexible Vehicle Air Pipe With Support Rings for Negative Pressure Stability

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Solution Overview

Problem

Existing air ducts for motor vehicles face challenges in withstanding high thermal and mechanical loads, maintaining dimensional stability, and ensuring reliability under varying operating conditions, particularly due to temperature differences and mechanical stresses, while also requiring cost-effective production and easy assembly.

Innovation Solution

The air duct features support rings made of dimensionally stable material surrounding a flexible line section with a free cross-section, allowing for stabilization and adaptation to mechanical stresses, and is manufactured using a 2-component injection molding process for precise control of wall thickness and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the air duct uses a flexible line section to compensate for thermal expansion and mechanical vibrations, then the adaptability and durability are improved, but the structural stability and resistance to negative pressure deteriorate

Engineering Contradiction:

Improvecompensation for thermal expansion and mechanical vibrationsVSAvoidresistance to negative pressure and structural stability

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The air duct employs a flexible line section with a bellows-like structure comprising multiple alternating elevations and depressions. This flexible shell design allows the duct to expand and contract thermally and mechanically while maintaining integrity under negative pressure through its geometric reinforcement.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible line section features a curved, bellows-like geometry with alternating elevations and depressions. This curvature provides structural reinforcement against collapse under negative pressure while preserving flexibility for thermal and mechanical compensation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Ease of manufacture

If the air duct is produced using blow molding process, then the manufacturing simplicity and cost are improved, but the manufacturing precision of wall thickness and mechanical properties deteriorate

Engineering Contradiction:

Improveproduction simplicity and costVSAvoidwall thickness uniformity and mechanical property control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent utilizes the inherent parameters of the blow molding process, including material selection (polyolefin, polypropylene, polyethylene), processing temperature ranges, and molding pressure variations, to achieve controlled wall thickness and mechanical properties while maintaining manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bellows-like structure with alternating elevations and depressions creates local variations in wall thickness and rigidity. Thicker walls are positioned at elevation points for strength, while thinner sections at depression points provide flexibility, optimizing both mechanical performance and material efficiency.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the air duct has a bellows-like structure with elevations and depressions, then the flexibility and vibration absorption are improved, but the wall thickness uniformity and manufacturing control deteriorate

Engineering Contradiction:

Improveflexibility and vibration absorptionVSAvoidwall thickness control in curved areas

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The bellows-like structure intentionally creates local quality variations with alternating elevations and depressions. The elevation points have increased wall thickness for structural support, while depression points have reduced thickness for flexibility, with each local variation optimized for its specific functional requirement.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curved bellows geometry with controlled elevations and depressions provides inherent structural reinforcement. The curvature distribution is designed to maintain wall thickness within acceptable tolerances while maximizing flexibility and vibration absorption capabilities.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentEP3791101B1Air pipe for motor vehicles

Publication Date: 2022.01.19 MONTAPLAST

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AI summary

The invention relates to an air pipe for motor vehicles, in particular for connecting a hot component to a cold component, wherein, at a first end of the pipe, first connecting means are provided for securing the pipe in an airtight manner to a hot component and, at the second end of the pipe, second connecting means are provided for securing the pipe in an airtight manner to a cold component, wherein at least one flexible pipe portion is provided between the first and the second connecting means, and wherein the pipe has a free pipe cross section. According to the invention, supporting rings made from a material which is dimensionally stable in relation to the flexible pipe material are provided, said supporting rings surrounding the free pipe cross section and stabilizing the cross-sectional shape of the flexible pipe portion.