Foam Duct Structure With High-Foam Bends for Insulation and Impact
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Solution Overview
Problem
Foam ducts used in vehicles often suffer from inadequate heat insulation and shock absorption due to thin portions formed during molding, leading to condensation and breakage when subjected to impacts.
Innovation Solution
Incorporating high-foam wall portions with a higher expansion ratio than other sections in the foam duct, particularly in bent portions, to enhance both heat insulation and shock absorption properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the foam parison is extended along contours of the cavity to form the foam duct, then the foam duct can be shaped to fit the vehicle interior, but thin portions are formed in bent areas which reduce heat insulation and shock absorption properties
Solution Approach 1:
The patent applies local quality by creating high-foam wall portions with higher expansion ratios specifically in bent portions of the foam duct, while other portions maintain standard foam density. This localized variation in foam structure provides enhanced heat insulation and shock absorption exactly where needed (in bent portions) without compromising the overall shape conformity to the vehicle interior cavity.
2Weight of moving object
If the foam duct is made lightweight using foam resin, then fuel efficiency is improved, but thin portions formed during molding are easily broken when subjected to impacts
Solution Approach 1:
The patent maintains the lightweight advantage of foam resin overall while locally reinforcing bent portions through high-foam wall portions with higher expansion ratios. This creates a gradient structure where thin portions in bent areas have increased foam density and cell wall thickness, providing enhanced impact resistance and break resistance exactly where structural stress occurs, while other portions remain lightweight.
3Quantity of substance
If the foam duct has thin portions in bent areas, then material usage is reduced and weight is decreased, but condensation occurs due to insufficient heat insulation
Solution Approach 1:
The patent optimizes material distribution by creating high-foam wall portions with higher expansion ratios specifically in bent portions where condensation is most likely to occur. This localized increase in foam density and thermal insulation capacity prevents condensation in critical areas while maintaining reduced overall material usage and weight compared to uniform thick-walled foam ducts.
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 portions effectively prevent condensation and mitigate shock impacts, while improving fluid flow efficiency by reducing resistance on the inner surface of the foam duct.
Implementation Method 1
the extended portion becomes thinner, to form a thin portion in the foam duct depending on cases. When such thin portion is formed, sufficient heat insulation is not obtained and condensation takes place in the thin portion
Implementation Method 2
the thin portion is easily broken when the foam duct falls on, for example, a floor or collides with another member. It is hence required to remove these problems by providing the foam duct with a heat insulating property and a shock absorbing property
Data Source
AI summary
A foam duct to which a heat insulating property and a shock absorbing property can be is provided due to structure of the foam duct is a foam duct including foam resin and includes a high-foam wall portion having a higher expansion ratio than other wall portions.