Foam duct
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Solution Overview
Problem
Existing foam ducts lack sufficient heat insulation and shock absorption properties, particularly in bent portions, leading to condensation and easy breakage when subjected to impact.
Innovation Solution
Incorporating a high-foam wall portion with a higher expansion ratio in bent portions of the foam duct, which increases thickness and provides improved heat insulation and shock absorption, while maintaining a soft structure for easy connection with other members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the foam duct uses uniform wall thickness, then the manufacturing process is simple, but the bent portions have insufficient heat insulation and are prone to condensation
Solution Approach 1:
The patent applies local quality by creating a non-uniform wall thickness distribution where bent portions have greater thickness than straight portions. This is achieved through controlled foaming expansion during molding, where the foam resin expands more in bent sections to form high-foam wall portions with larger bubble diameters and higher expansion ratios, providing enhanced heat insulation precisely where needed without increasing overall complexity
2Device complexity
If the foam duct has uniform wall thickness, then the structure is simple, but the bent portions have insufficient shock absorption and are easily broken
Solution Approach 1:
The patent implements local quality by concentrating shock absorption capabilities in bent portions through high-foam wall portions with larger bubble diameters and higher expansion ratios. These localized high-foam regions provide enhanced energy absorption and impact resistance precisely where the duct is most vulnerable, while maintaining simpler structure in straight portions
3Temperature
If the foam duct uses high expansion ratio in bent portions, then heat insulation and shock absorption are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by controlling the expansion ratio of foam resin during the molding process. By adjusting foaming conditions and resin properties, the process creates high-foam wall portions with larger bubble diameters and higher expansion ratios in bent sections, achieving enhanced heat insulation and shock absorption through controlled material parameter variations rather than complex structural modifications
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 high-foam wall portion effectively prevents condensation and mitigates shock impact, enhancing both heat insulation and shock absorption properties without compromising the duct's flexibility and connection stability.
Implementation Method 1
the high-foam wall portion 204 having a higher expansion ratio than other wall portions... to provide the foam duct with a heat insulating property
Implementation Method 2
the high-foam wall portion 204 having a higher expansion ratio than other wall portions... to provide the foam duct with a shock absorbing property
Data Source
Figure 1
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Figure 4~5
AI summary
A foam duct (200) to which a heat insulating property and a shock absorbing property is provided due to structure of the foam duct is a foam duct including foam resin and includes a high-foam wall portion (204) having a higher expansion ratio than other wall portions.