Polymeric Retaining Clip Isolates Seal Forces in Clean Air Duct
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Solution Overview
Problem
Existing air ducts for automotive applications are heavy, bulky, and prone to leakage due to the use of metal hose clamps, which are time-consuming to assemble and can corrode, leading to a compromised seal under vibration and flexure forces.
Innovation Solution
A clean air duct assembly featuring a tubular body with a cuff and a retaining clip that secures the cuff to a receiving port using a polymeric material, eliminating the need for metal hose clamps and providing a secure, tool-free assembly with enhanced sealing capabilities through flexible fins and a clip design that isolates the seal from vibration and flexure forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal hose clamp is used to secure the cuff to the receiving port, then the connection is secure and prevents air leakage, but the assembly is time-consuming and the metal band may cut into the cuff causing tears and leakage
Solution Approach 1:
The patent extracts the fastening function from the traditional metal hose clamp and redistributes it to two separate components: the cuff with its integrated sealing features and the retaining clip. This eliminates the need for tools and complex assembly while maintaining seal integrity through the cuff's flexible fins that conform to the receiving port.
Solution Approach 2:
The patent introduces a polymeric retaining clip as an intermediary component between the cuff and the receiving port. This clip provides the necessary mechanical retention without the harmful cutting effects of metal clamps, while the cuff's flexible fins act as an intermediary sealing element that conforms to the port surface.
2Reliability
If a metal hose clamp is used to secure the cuff, then the connection is secure, but the metal may corrode over time causing the sealed connection to fail
Solution Approach 1:
The patent changes the material parameter of the retaining component from metal to polymer, fundamentally altering the corrosion resistance property. The polymeric retaining clip and cuff materials are selected to be immune to corrosion while maintaining adequate mechanical strength and retention capabilities.
Solution Approach 2:
The patent employs composite material construction with the cuff made from flexible polymeric material and the retaining clip made from rigid or semi-rigid polymeric material. This combination provides both the sealing flexibility and the retention strength needed, while both materials offer superior corrosion resistance compared to metal.
3Reliability
If the cuff is secured with a hose clamp, then the connection is secure, but the seal is not adequately isolated from vibration and flexure forces causing seal degradation
Solution Approach 1:
The patent segments the connection system into distinct functional zones: the sealing zone with flexible fins that isolate the seal from forces, the retention zone with the retaining clip that handles mechanical loads, and the transition zone that connects these functions. This segmentation allows each component to specialize in its function without compromising the other.
Solution Approach 2:
The patent uses the cuff's flexible fins as an intermediary sealing element that is deliberately isolated from vibration and flexure forces by the retaining clip structure. The retaining clip acts as a mediator that absorbs mechanical stresses while the flexible fins maintain the seal in a protected, stable position.
4Reliability
If a one-piece rubber molded air duct is used, then the duct is effective at sealing, but it is too heavy for vehicles requiring lighter weight
Solution Approach 1:
The patent divides the air duct system into separate components: a lightweight thermoplastic tubular body and a separate cuff assembly with retaining clip. This segmentation allows the use of lighter materials while maintaining sealing effectiveness through the specialized cuff design with flexible fins.
Solution Approach 2:
The patent transitions from solid rubber material to a composite construction using thermoplastic for the tubular body and flexible polymeric material for the cuff. This material substitution significantly reduces weight while the flexible polymeric cuff maintains sealing effectiveness through its fin structure that conforms to the receiving port.
5Weight of moving object
If a two-piece construction with thermoplastic body and rubber cuff is used, then the duct is lighter, but it still requires a hose clamp that is time-consuming to assemble
Solution Approach 1:
The patent merges the retention and sealing functions into an integrated cuff-clip assembly. The cuff is designed with built-in flexible fins for sealing and the retaining clip is configured to work seamlessly with the cuff, eliminating the need for separate hose clamp assembly and reducing overall assembly time.
Solution Approach 2:
The patent extracts the fastening function from the traditional hose clamp and redistributes it to the retaining clip and cuff combination. This reassignment eliminates the need for tools and complex assembly procedures while maintaining secure connection, thereby reducing assembly time.
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 results in a lightweight, cost-effective, and reliable air duct assembly that reduces assembly time, prevents corrosion, and maintains a secure seal over time, even under operational vibrations.
Implementation Method 1
the cuff includes at least one flexible fin that seals around the port when the deflectable clip and cuff are installed on the receiving port such that the clip provides a stress relief so as to isolate the flexible fins from the clean air duct
Data Source
AI summary
A clean air duct and retaining clip assembly for installation on a receiving port includes a tubular body, and a cuff, which extends from the tubular body, that includes a collar, a retention groove adjacent the collar, and a sealing section adjacent the retention groove. A retaining clip is received around the cuff and has at least one inwardly extending cuff strut received therein to hold the cuff on the receiving port and isolate the sealing section, which is also received on the receiving port, from forces applied to the tubular body. The retaining clip includes an arcuate clip body with an external surface opposite an internal surface connected by opposed edges. At least one pair of struts extends inwardly from the internal surface, where one of the struts is proximal one of the edges and the other is proximal the opposite edge.