Two-Part Plastic Air Volume Flow Controller for Tool-Free Assembly
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Solution Overview
Problem
Existing volume flow controllers for air conditioning systems are complex and costly to assemble, often requiring additional tools and drilling, which increases production costs and complexity.
Innovation Solution
A device comprising two interlocking pipe parts made of plastic, designed to accommodate the flap axis without additional tools, using a tongue-and-groove locking mechanism and cross-shaped recesses for secure assembly, allowing for easy assembly and reduced manufacturing costs through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the component is made from a single piece requiring drilling and additional tools for assembly, then the assembly precision and structural integrity are improved, but the ease of manufacture and production cost increase
Solution Approach 1:
The component is divided into two separate pipe parts that can be manufactured using injection molding and then assembled together using a tongue-and-groove locking mechanism. This segmentation allows each part to be produced independently with standard manufacturing processes, reducing overall production cost while maintaining assembly precision through the interlocking design.
Solution Approach 2:
One pipe part is inserted into the other pipe part, with the flap axis nested between them. The tongue-and-groove locking mechanism enables one component to be securely positioned within another, achieving precise assembly without requiring drilling or additional fastening tools.
2Reliability
If the component requires drilling and additional tools for assembly, then the structural integrity and locking reliability are improved, but the device complexity and assembly time increase
Solution Approach 1:
The locking mechanism is segmented into distinct tongue and groove elements that interlock mechanically. This segmentation provides reliable locking through the interlocking geometry while keeping the assembly process simple and tool-free.
Solution Approach 2:
The tongue-and-groove locking mechanism is designed to self-align and self-lock when the two pipe parts are assembled. The flap axis automatically positions itself between the pipe parts, and the locking tongues engage with the grooves without requiring external tools or complex assembly procedures.
3Manufacturing precision
If the component is designed as a single integrated part, then the manufacturing precision and structural strength are improved, but the ease of operation and assembly simplicity deteriorate
Solution Approach 1:
The component is segmented into two injection-molded pipe parts that maintain high manufacturing precision through standard molding processes. The segmentation improves assembly simplicity by allowing the parts to be connected through a straightforward tongue-and-groove mechanism without requiring complex drilling or fastening operations.
Data Source
Figure 1
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AI summary
The device (P) has a flap rotatably arranged in a component (1) of a pipeline system around a flap axle. The component is divided into two pipe parts (2.1, 2.2) perpendicular to and towards a longitudinal axis of the pipeline system, and parts e.g. shells and stub shafts (11), of the axle are accommodated between the pipe parts of the component. The pipe parts are made of plastic material. The pipe parts and/or the shells comprise spring- and groove-shaped recesses or projections co-acting with one another, and a bearing point for the axle. An independent claim is also included for a method for manufacturing a device for controlling volumetric air flow in a pipeline system of an air-conditioning system.