Composite Plastic Gas Duct With Non-Woven Sound Absorption
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Solution Overview
Problem
Existing gas ducts made from molded plastic materials lack adequate sound absorption characteristics, leading to noise issues like rattling and squeaking, and are often heavy, making them unsuitable for lightweight and efficient applications.
Innovation Solution
A gas duct with a channel body made from plastic material that incorporates a sound absorbing component with a non-woven layer, where the non-woven layer is locally weakened to form a hinge and over-molded with the plastic material, creating a durable and rattle-free connection, enhancing sound absorption and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molded plastic material is used for gas duct, then structural integrity is improved, but weight increases and sound absorption deteriorates
Solution Approach 1:
The gas duct combines plastic material with a sound absorbing component made of porous material, creating a composite structure that integrates both structural integrity and sound absorption functions in a single lightweight component
2Strength
If molded plastic material is used for gas duct, then structural integrity is improved, but sound absorption deteriorates
Solution Approach 1:
The gas duct combines plastic material with a sound absorbing component made of porous material, creating a composite structure that integrates both structural integrity and sound absorption functions in a single lightweight component
Solution Approach 2:
The sound absorbing component is made from porous material with controlled pore structure that allows air permeability while providing effective sound absorption characteristics
3Strength
If rigid parts are connected with fasteners, then assembly strength is improved, but rattling and squeaking increase
Solution Approach 1:
The sound absorbing component acts as a flexible damping layer between rigid parts, absorbing vibrations and preventing rattling and squeaking noises while maintaining assembly strength
Solution Approach 2:
The combination of plastic material and porous sound absorbing component creates a composite structure that provides both structural integrity and vibration damping properties
4Object-affected harmful factors
If sound absorbing component is added to gas duct, then sound absorption is improved, but device complexity increases
Solution Approach 1:
The sound absorbing component is integrated directly into the gas duct body as a single molded part, combining the duct structure and sound absorption function into one component rather than separate assemblies
Solution Approach 2:
The sound absorbing component serves multiple functions simultaneously: sound absorption, vibration damping, and structural integration, reducing the need for additional separate components
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 improved sound absorption and reduced weight, achieving noise reduction and lighter weight while maintaining structural integrity, suitable for applications like HVAC and battery systems.
Implementation Method 1
The molded plastic material penetrates the porous material and solidifies there, creating a material bond between the channel body and the sound absorbing component
Implementation Method 2
a sound absorbing component being made at least partially from at least one non-woven layer
Data Source
Figure 1~2
Figure 3
AI summary
The present teachings relate generally to a gas-duct whose channel body is manufactured from a plastic material, wherein the channel body has at least one region replaced by a sound absorbing component being made at least partially from at least one non-woven layer. The present invention further relates to a HVAC- and Battery- and/or battery-charge-system and to a method of producing a gas-duct.