Vehicle Body Duct Nesting for Packaging Space
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Solution Overview
Problem
Routing ventilation ducts between vehicle body structures and tightly packaged interior components is challenging due to limited space, requiring innovative methods to save packaging space while maintaining structural integrity and controlling duct position.
Innovation Solution
The vehicle body structure incorporates a duct system with a body disposed within the interior space of a panel and outlets extending through flanged portions, allowing for conditioned air to be routed to the passenger compartment without weakening the structure, using materials like foam or extruded plastic and thermal treatment to form the duct within the body structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ventilation ducts are routed between body structures and interior components, then conditioned air can be delivered to the passenger compartment, but packaging space is limited and structural integrity may be compromised
Solution Approach 1:
The ventilation duct is nested within the body structure by forming it inside the interior space defined by panels during the stamping process. The duct body is formed within the cavity created by the panels, and outlets extend through flanged portions that are integrated into the body structure, allowing the duct to occupy space that would otherwise be structural material.
Solution Approach 2:
The duct is formed in the interior space of the stamped panel structure, utilizing the third dimension (depth/thickness of the panel) rather than only the two-dimensional surface area. This allows the duct to be routed through the body structure itself rather than alongside it, saving packaging space.
2Manufacturing precision
If duct outlets extend through flanged portions of panels, then duct position is controlled and air routing is improved, but structural strength may be reduced
Solution Approach 1:
The duct outlets are merged with the flanged portions of the panels during the stamping process. The outlets extend through the flanged portions which are then formed into the final body structure, integrating the duct positioning function with the structural panel itself rather than treating them as separate components.
Solution Approach 2:
The duct body and outlets are formed in their final positions within the panel interior space and flanged portions during the initial stamping process, before the body structure is assembled into the vehicle. This preliminary formation ensures precise duct positioning and eliminates the need for separate installation steps that could compromise structural integrity.
3Reliability
If a coating is deposited and heat treated to form the duct, then the duct is integrated into the body structure, but additional manufacturing steps are required
Solution Approach 1:
The coating material undergoes a parameter change through heat treatment, transforming from a deposited coating layer to a formed duct structure with defined geometry and outlets. The heat treatment process changes the physical state and shape of the coating material, integrating it into the final body structure as a functional duct component.
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
This solution effectively routes conditioned air to the passenger compartment while preserving packaging space and maintaining the structural integrity of the vehicle body, allowing for better control of air temperature and reducing noise and vibration concerns.
Implementation Method 1
Heat treatment of the coating forms a duct having a body extending along the interior space and an outlet that extends from the body through the passageway
Data Source
AI summary
A vehicle body structure located adjacent to a passenger compartment of a vehicle includes a first wall defining an interior space adjacent to the first wall; a second wall extending outward from the first wall and defining a passageway in communication with the interior space; and a duct having a body that is disposed in the interior space of the first wall and an outlet that extends outward from the body and is disposed in the passageway of the second wall. The duct routes conditioned air from the body through the outlet to the passenger compartment of the vehicle.