Vehicle Air Nozzle With Wavy Contour for Stability and Noise Control
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Solution Overview
Problem
Existing air nozzles for heating, ventilation, and air conditioning systems in vehicles face challenges in achieving mechanical stability and favorable airflow behavior while maintaining cost-effectiveness and simplicity, often resulting in distortion or acoustic issues like whistling noises due to the use of flat plastic components.
Innovation Solution
The air nozzle design features components with a wavy cross-sectional contour, made from hard plastic with optional soft plastic segments, allowing for injection molding simplicity and mechanical stability, and incorporating a three-dimensional wave-shaped surface to guide airflow effectively without noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat plastic components are used for guiding air, then manufacturing simplicity and cost-effectiveness are improved, but mechanical stability and resistance to distortion deteriorate
Solution Approach 1:
The patent applies curvature by designing the plastic guiding components with a wavy cross-sectional contour instead of a flat shape. This curved geometry provides structural rigidity and resistance to distortion while maintaining the advantage of simple injection molding manufacturing. The wavy profile acts similarly to corrugated structures in engineering, where curvature enhances mechanical strength without adding complexity to the manufacturing process.
2Ease of manufacture
If flat plastic components are used for guiding air, then manufacturing cost is reduced, but acoustic issues like whistling noises occur
Solution Approach 1:
The wavy cross-sectional contour of the guiding components modifies the airflow pattern by creating a more gradual pressure distribution and reducing turbulence. The curved surfaces guide air smoothly around corners and edges, preventing the formation of vortices and pressure differentials that cause whistling noises, while the components remain inexpensive to manufacture via injection molding.
3Stability of the object's composition
If components with wavy cross-sectional contour are used, then mechanical stability and airflow guidance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single component design. The wavy cross-sectional contour simultaneously provides structural rigidity for mechanical stability, guides airflow effectively to prevent distortion, and reduces acoustic issues. This integrated approach eliminates the need for separate reinforcement elements or complex assembly structures, keeping the overall manufacturing process simple despite the curved geometry.
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 design ensures mechanical stability, prevents distortion, and achieves a widened, soft, and diffuse airflow without acoustic issues like whistling, while maintaining cost-effectiveness and simplicity in manufacturing.
Implementation Method 1
at least one component (33, 1) for guiding the air flow has a base body (2) with a wavy cross-sectional contour
Data Source
Figure 1~2
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Figure 5~8
AI summary
The air nozzle, in particular, for guiding an air stream in ventilation and air-conditioning units in motor vehicles comprises a housing (1) (3) accommodating an array of plates (3) with a straight front edge and a wavy rear section.