Plastic Throttle Flap Assembly for Faster HVAC Installation
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Solution Overview
Problem
Throttle flaps in ventilation and air-conditioning systems are structurally complex and time-consuming to assemble due to the number of components, leading to increased manufacturing and installation complexity.
Innovation Solution
A flap and mounting frame assembly unit made of plastic, where the flap is pivotally mounted within a central shaft, simplifying the design and assembly process, with features like a collar for guiding airflow and anti-twist mechanisms to prevent unintentional loosening, and adjustable elements for easy positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a throttle flap is made of sheet metal with a separate shaft or axle for rotational mounting, then the flap can be rotatably mounted in a ventilation duct, but the structure becomes complex and assembly/installation becomes time-consuming
Solution Approach 1:
The patent combines the throttle flap and mounting frame into a single integrated assembly unit made of plastic. The mounting frame is formed as one piece with the flap, eliminating the need for separate shafts or axles. The plastic material allows for integrated manufacturing of multiple components that were previously separate, thereby reducing structural complexity while maintaining the rotational mounting capability through the integrated design.
Solution Approach 2:
The patent utilizes plastic material to manufacture both the flap and mounting frame, replacing traditional sheet metal construction. This material choice enables complex geometries to be formed in single pieces, facilitates integration of multiple components into one assembly unit, and allows for easier assembly through features like snap-fits and integrated mounting elements, thereby reducing overall device complexity.
2Adaptability or versatility
If multiple separate components are used for the throttle flap assembly, then functional requirements can be met, but manufacturing and assembly time increases
Solution Approach 1:
The patent integrates the mounting frame and throttle flap into a single assembly unit manufactured as one piece or pre-assembled unit. This integration eliminates multiple separate manufacturing and assembly steps, reducing production time and assembly complexity while maintaining all necessary functions through the unified design. The integrated structure allows for factory pre-assembly, enabling quick installation on-site.
Solution Approach 2:
The mounting frame and flap are designed to be pre-assembled into an integration unit during factory production, with all necessary mounting features, shafts, and adjustment mechanisms already in place. This preliminary assembly allows the complete functional unit to be manufactured and tested before delivery, significantly reducing on-site assembly time and complexity while ensuring all functional requirements are met.
Data Source
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AI summary
The invention relates to a flap (1), in particular a throttle flap, for influencing a volume flow in a ventilation and air-conditioning system. In order to specify a flap that has a simpler design and is also easier to manufacture and assemble, the flap (1) should be arranged in an installation frame (2) with an opening and the flap and the installation frame form an assembly unit, with the flap being pivotable around a shaft (3) or axle arranged in particular in the middle of the opening is mounted in the opening, and the mounting frame and the flap are each made of plastic.