Injection-Molded Vehicle Pressure Relief Valve With Leak-Tight Flaps
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Solution Overview
Problem
Existing pressure relief valves for vehicle compartments are often multi-part assemblies that are costly, prone to assembly variability, generate noise, and fail to provide a sufficient seal, allowing external air, moisture, and noise to enter the vehicle compartment.
Innovation Solution
A one-piece, injection molded pressure relief valve apparatus with integrally formed flaps and frame, using different polymer materials for rigidity and flexibility, and noise-reducing features to ensure a leak-proof seal and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-part assemblies are used for pressure relief valves, then assembly flexibility and adjustability are improved, but manufacturing cost increases, assembly variability increases, and sealing reliability deteriorates
Solution Approach 1:
The patent merges multiple separate components (frame, flaps, seals, hinges) into a single integrated injection molded piece. The valve body, flaps, sealing elements, and hinge mechanisms are all formed as one unified structure, eliminating assembly variability and improving sealing reliability while reducing manufacturing steps.
Solution Approach 2:
The patent utilizes composite material properties by incorporating different polymer materials within the single molded piece. The frame uses rigid material for structural support, while the flaps and sealing portions use flexible materials for proper sealing and movement, achieving both structural integrity and sealing reliability in one component.
2Ease of repair
If separate components are used for pressure relief valves, then ease of repair and replacement are improved, but device complexity increases, manufacturing cost increases, and noise increases
Solution Approach 1:
The patent combines all valve components into one integrated piece, reducing the number of parts from multiple separate components to a single unit. This simplifies the device structure, reduces manufacturing complexity, and minimizes noise from multiple moving parts while maintaining functionality.
3Adaptability or versatility
If traditional multi-part valves are used, then adjustability is improved, but productivity decreases due to multiple assembly steps, and manufacturing precision deteriorates due to assembly variability
Solution Approach 1:
The patent performs all adjustments and positioning actions during the injection molding process itself. The flaps are pre-positioned and pre-adjusted to their correct orientations and sealing positions while being molded, eliminating the need for post-assembly adjustments and improving manufacturing efficiency and precision.
4Strength
If rigid materials are used for the valve frame, then structural strength is improved, but sealing capability deteriorates due to lack of flexibility
Solution Approach 1:
The patent uses different polymer materials for different portions of the single molded piece. The frame is made from rigid material (e.g., polypropylene or polycarbonate) for structural strength, while the flaps and sealing surfaces are made from flexible materials (e.g., thermoplastic elastomers) that can deform to create tight seals, achieving both strength and sealing capability in one component.
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 solution provides a cost-effective, noise-reduced, and leak-proof pressure relief mechanism that effectively vents excess pressure while preventing unwanted air and moisture entry, enhancing vehicle compartment integrity.
Implementation Method 1
the first flap is sufficiently flexible to bend about a line adjacent the edge... the flaps are bent away from the as-molded configurations, thereby generating elastic force urging the flaps toward the respective valve seats
Implementation Method 2
pressurized air at the interior face of the frame to vent through the flow opening... when the first flap is pressed against the first valve seat by a positive pressure differential between the vehicle compartment and the outside environment
Data Source
AI summary
A pressure relief valve apparatus for a vehicle compartment includes (a) a housing having an injection molded frame for mounting in an aperture in a vehicle panel, the frame having at least one flow opening extending therethrough; and (b) at least one injection molded flap, each flap having a flap connection portion joined to the frame adjacent an upper edge of a respective flow opening. Each flap is pivotable between a closed position in which the respective flow opening is blocked by the flap, and an open position in which the respective flow opening is unblocked for permitting pressurized air to vent through the flow opening.