Integrated Vehicle Air Duct with Pliable Bellows Section

Solution Overview

Problem

Conventional air ducts for vehicles have complex structures due to multiple components, leading to increased cost, weight, and compromised sealing and vibration-damping features.

Innovation Solution

An air duct formed as a single unit with a rigid and pliable component, where the pliable component is injection-molded with circumferentially disposed coupling apertures and ribs, integrated with a bellows shape to enhance coupling and sealing, reducing the number of components and improving vibration-damping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple components are assembled together to form the air duct, then the structure can be flexible and adaptable, but the device complexity increases, weight increases, and sealing performance deteriorates

Engineering Contradiction:

Improvestructural flexibilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate air duct components (upper duct, lower duct, bellows duct, adapter) into a single integrated air duct component. This is achieved by providing a continuous outer surface that forms different sections (first, second, third, and fourth sections) of the air duct, eliminating the need for separate components and their associated coupling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single air duct component performs multiple functions that were previously distributed across different components: it serves as the upper duct, lower duct, bellows duct, and adapter simultaneously. The continuous outer surface is configured to define multiple functional sections including the air intake passage, bellows section, and coupling interfaces with the air filter assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple components are assembled together to form the air duct, then the structure can be flexible and adaptable, but the weight increases

Engineering Contradiction:

Improvestructural flexibilityVSAvoidair duct weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent merges multiple separate air duct components (upper duct, lower duct, bellows duct, adapter) into a single integrated air duct component. This is achieved by providing a continuous outer surface that forms different sections (first, second, third, and fourth sections) of the air duct, eliminating the need for separate components and their associated coupling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple components are assembled together to form the air duct, then the structure can be flexible and adaptable, but the sealing performance deteriorates

Engineering Contradiction:

Improvestructural flexibilityVSAvoidsealing feature

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges multiple separate air duct components (upper duct, lower duct, bellows duct, adapter) into a single integrated air duct component. This is achieved by providing a continuous outer surface that forms different sections (first, second, third, and fourth sections) of the air duct, eliminating the need for separate components and their associated coupling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent addresses the potential harm of having multiple coupling interfaces (which create leakage points) by converting the design into a single-component structure where the continuous outer surface eliminates these interfaces. The bellows section maintains flexibility while the integrated structure ensures continuous sealing throughout the entire air duct assembly.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Adaptability or versatility

If multiple components are assembled together to form the air duct, then the structure can be flexible and adaptable, but the vibration-damping feature deteriorates

Engineering Contradiction:

Improvestructural flexibilityVSAvoidvibration damping

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple separate air duct components (upper duct, lower duct, bellows duct, adapter) into a single integrated air duct component. This is achieved by providing a continuous outer surface that forms different sections (first, second, third, and fourth sections) of the air duct, eliminating the need for separate components and their associated coupling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration minimizes weight and cost while enhancing sealing and vibration-damping, preventing pressure loss and improving noise, vibration, and harshness (NVH) performance.

Implementation Method 1

The second duct component may be injection-molded and the second duct component may be circumferentially disposed on a first (e.g., one) side thereof with a plurality of coupling apertures. The first duct component may be injection-molded into one piece with the second duct component

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

an air duct that is fabricated as a single unit that provides an improved vibration-damping feature

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 3

a second duct component formed from a pliable (e.g., soft) material through which suctioned air may be discharged towards an air filter

Methodology Applied

Scientific EffectPliable material properties: Viscoelasticity

Implementation Method 4

The second duct component may have a bellows shape. The second duct component may be circumferentially disposed on a second (e.g., the other) side thereof and may include plurality of ribs disposed (e.g., inclined) at a predetermined angle

Methodology Applied

Scientific EffectBellows structure: Corrugation

Data Source

PatentUS9643483B2Air duct for vehicle

Publication Date: 2017.05.09 HYUNDAI MOTOR CO LTD

AI summary

An air duct for a vehicle is provided. The air duct includes a first duct component that is formed from a rigid material through which air external air is introduced. A second duct component is formed from a pliable material through which introduced air is discharged towards an air filter. The second duct component is formed integrally with the first duct component.