Pivoting Baffle Assembly with Living Hinges for Fluid Routing
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Solution Overview
Problem
The existing baffle systems require multiple separate parts and manufacturing steps to form complex shapes or features, leading to increased costs and opportunities for installation errors, particularly in applications like fluid routing within body cavities, where mirror-image parts can be easily confused.
Innovation Solution
A baffle assembly featuring two interconnected baffles with a connecting member and living hinges, allowing them to pivot and form distinct shapes or features on a panel, along with error-proofing mechanisms like offset attachment members and fins to prevent incorrect installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate baffles are used to form complex shapes or features, then the ability to properly route fluid flow and form distinct shapes is improved, but the number of parts and manufacturing operations increases, leading to increased costs and opportunities for installation errors
Solution Approach 1:
The patent combines multiple separate baffles into a single integrated baffle assembly that can form multiple distinct shapes and features. The assembly includes a first baffle and a second baffle connected by a connecting member, allowing them to function as one unit while maintaining their individual shaping capabilities. This reduces the number of separate parts and manufacturing operations required.
Solution Approach 2:
The baffle assembly incorporates living hinges that allow the baffles to pivot and adjust to different positions. This dynamic capability enables the assembly to adapt to various installation configurations and properly route fluid flow in different scenarios, while still being manufactured as a single integrated piece.
2Manufacturing precision
If multiple separate baffles are used, then distinct shapes or features can be formed, but the number of installation steps increases and the risk of incorrect installation increases due to similar mirror-image parts
Solution Approach 1:
The connecting member is configured with an asymmetric geometry that prevents the baffle assembly from being installed in the wrong orientation. The connecting member extends between the first and second baffles in a specific configuration that only fits the intended installation position, eliminating the possibility of incorrect installation of mirror-image versions.
Solution Approach 2:
The connecting member acts as an intermediary element that links the first and second baffles in a fixed spatial relationship. This intermediary structure ensures that the baffles are positioned correctly relative to each other and to the panel, preventing installation errors that could occur with separate mirror-image parts.
3Adaptability or versatility
If multiple separate baffles are manufactured and installed, then complex features can be created, but manufacturing costs and installation time increase
Solution Approach 1:
The patent merges multiple baffle manufacturing operations into a single integrated manufacturing process. The first and second baffles are formed as part of a single molded piece, eliminating the need to manufacture, handle, and install separate parts. This significantly improves manufacturing efficiency and reduces installation time.
Solution Approach 2:
The baffle assembly is pre-configured with the connecting member and living hinges during manufacturing, so that the complex multi-baffle structure is ready for installation as a single unit. The living hinges are pre-formed to allow the baffles to pivot into their final positions, eliminating the need for complex assembly operations at the installation site.
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 solution reduces the number of separate baffles needed, simplifies the manufacturing process, and prevents incorrect installations by ensuring accurate alignment and orientation, thereby reducing manufacturing costs and warranty issues.
Implementation Method 1
An expandable material may be provided on the carrier that may be expanded, such as by the application of heat, to form a material which improves structural qualities of any panels or structural members in contact with the expanded material
Implementation Method 2
Some expandable materials may form a foam material after expansion that dampens transmission of sound through the structure by absorbing sound energy or dampening vibrations of a structure
Implementation Method 3
two baffles, each having a rigid carrier and an expandable material, which are linked by a connecting member which allows each baffle to pivot about the connecting member
Data Source
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AI summary
A baffle assembly (100) for engaging a panel and a method of manufacturing the same are disclosed. A baffle assembly may include at least two baffles (104, 106), each having a rigid carrier (110, 112) and an expandable material (114, 116), which are linked by a connecting member (102) which allows each baffle to pivot about the connecting member. The baffles may each include an attachment member (105, 107) configured to engage a first aperture (204) and a second aperture (206), respectively, in a panel (202). A method of manufacturing a carrier for engaging a panel may include forming at least two baffles, and forming a connecting member between the baffles that allows the baffles to pivot about the connecting member.