Foldable Duct End Connection for Secure Vent Attachment
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Solution Overview
Problem
Existing lightweight ducts, particularly those made of foam or plastic, face challenges in creating secure and efficient connections with other ducts or vents, requiring improved connectability and manufacturing methods to facilitate easy and reliable assembly in various applications such as vehicles and HVAC systems.
Innovation Solution
A connection mechanism featuring a duct with a flared section and inwardly foldable tapered flap section, which provides a secure connection when engaged with a vent or adapter, utilizing an adhesive for stability and tactile feedback, and can be manufactured using methods like twin sheet processing and molding to ensure structural integrity and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight foam or plastic ducts are used, then weight is reduced and flexibility is improved, but connection security and structural integrity deteriorate
Solution Approach 1:
The duct end is segmented into distinct functional zones: a flared section for engagement, a tapered flap section for folding and sealing, and an adhesive application area. This segmentation allows each zone to perform its specific function optimally, enabling secure connections in lightweight ducts without compromising structural integrity.
Solution Approach 2:
The tapered flap section is designed to be dynamically foldable inward, transitioning from an extended state to a folded state within the flared section. This dynamic movement allows the duct to adapt during connection, creating a secure fit that maintains reliability while keeping the overall duct structure lightweight.
2Reliability
If complex connection structures are added to improve connection security, then connection reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple connection functions are merged into a single integrated structure: the flared section provides both structural reinforcement and engagement geometry, while the tapered flap section simultaneously provides sealing and mechanical interlocking when folded. The adhesive layer is integrated into the flap section, combining chemical bonding with mechanical features. This merging reduces overall complexity compared to separate components.
Solution Approach 2:
The connection structure is designed to be self-securing through the inward folding of the tapered flap section within the flared section, creating automatic mechanical interlocking and sealing without requiring additional fasteners or complex assembly mechanisms. The adhesive provides self-bonding capability.
3Ease of manufacture
If traditional duct connection methods are used, then manufacturing simplicity is maintained, but connection efficiency and assembly ease deteriorate
Solution Approach 1:
The tapered flap section is pre-formed with the correct geometry and adhesive is pre-applied during duct manufacturing. This preliminary preparation allows for rapid assembly during installation, as the connection components are ready-to-use and require only simple folding and engagement actions, significantly improving assembly efficiency.
Data Source
AI summary
A duct is shaped and sized for connectability to a vent (or vent adaptor). The duct has an end portion with a flared section separated from a tapered flap section by a lip. The flaps are foldable inwardly at the lip upon engagement with the vent, and airflow through the duct presses the folded flaps against the vent for additional securement of the connection between same. Additional securement and stability may be provided by an adhesive retaining a tapered flap section to a flared section following inward folding of the tapered flap section.