Modular Thermoplastic Air Duct for Vehicle Panel Integration
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Solution Overview
Problem
The installation of air ducts in double-decker vehicles, such as rail vehicles, is challenging due to limited space, and existing solutions are costly and inefficient in utilizing available space.
Innovation Solution
A modular air duct system made from prefabricated thermoplastic duct modules using a twin-sheet process, where the deflection device is integrated within each module, allowing for space-saving installation and integration with vehicle paneling, with features like thermal insulation and maintenance openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If air ducts are installed separately from sheet metal in conventional methods, then installation flexibility is improved, but installation costs and time increase
Solution Approach 1:
The patent combines the air duct and paneling parts into a single integrated component manufactured from sheet metal. The air duct is formed as an integral part of the paneling structure, eliminating separate installation steps. This merging of functions reduces both cost and installation time while maintaining the adaptability to fit various vehicle configurations.
2Productivity
If more installation space is allocated for air ducts in double-decker vehicles, then air duct functionality is improved, but available space for other components decreases
Solution Approach 1:
The air duct is integrated into the paneling structure, allowing it to occupy space that would otherwise be unused or dedicated to non-structural elements. By combining the air duct with the paneling, the design achieves full air duct functionality without requiring additional dedicated installation space in the constrained upper deck environment.
Solution Approach 2:
The air duct utilizes the three-dimensional space within the paneling structure by forming channels and cavities within the paneling thickness. This approach transforms the available installation problem from a two-dimensional surface issue to a three-dimensional volumetric solution, maximizing space utilization in the constrained upper deck area.
3Ease of operation
If the deflection device is installed separately on the main channel as in prior art, then deflection functionality is achieved, but device complexity and installation steps increase
Solution Approach 1:
The deflection device is integrated directly into the air duct structure as a built-in feature rather than a separate component. The paneling structure itself incorporates deflection surfaces and channels that redirect airflow, eliminating the need for separate deflection devices and their associated installation steps, thereby reducing overall device complexity.
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 modular design facilitates easy installation, conserves space, and provides effective thermal insulation and maintenance access, making it suitable for tight spaces like upper decks of double-decker vehicles.
Implementation Method 1
A twin-sheet method is a vacuum deep-drawing method (thermoforming) with two plates lying one on top of the other in an initial position. In the twin-sheet process, the two sheets are subjected to heat either one after the other or simultaneously and are then formed.
Implementation Method 2
A twin-sheet method is a vacuum deep-drawing method (thermoforming) with two plates lying one on top of the other in an initial position.
Implementation Method 3
The duct modules can be covered with heat insulation at least on their side assigned to an interior of the vehicle. This results in favorable thermal insulation between the vehicle interior and the outside of the vehicle in which the air duct is installed.
Data Source
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AI summary
The invention relates to an air duct for installation in a vehicle (for example a rail vehicle) for transporting people, comprising a main duct for guiding air in a main direction and comprising a deflection device connected to the main channel for deflecting air flowing in from the main channel in a feed direction different from the main direction, wherein the air channel comprises a plurality of prefabricated duct modules (1), which have main duct portions (2) and are produced from a thermoplastic in a twinsheet method, and the duct modules (1) can be directly connected to one another in the main flow direction.