Patent Application
20180154736
The invention relates to a component, in particular an air-conducting component, and to a method for connecting components, in particular air-conducting components.
Air conduits, or air ducts, respectively, in vehicles are equipped with assembly elements in order to be linked to further components, for example to a further air duct, to a distributor housing, or to a pipe connector. For example, injection-molded plastic parts, cable ties, adhesive-mounted foam parts, or other separate parts, are used as assembly elements. The assembly elements often have to be adapted to the air ducts in a manner that is complex in terms of production technology, this causing additional costs. Further costs and an additional effort arise on account of seals to be inserted. Moreover, the known assembly elements often have the disadvantage that the technician is provided with insufficient feedback as to whether the air conduit has been connected adequately to the add-on part, or whether a permanent firm fit is guaranteed, respectively. Therefore, it is difficult for an adequately tight firm fit to be reliably guaranteed or ensured, respectively.
The invention is based on the object of providing a component, in particular an air-conducting component, which can be connected to a further component, in particular to a further air-conducting component, in a manner that is simple, reliable, and as far as possible cost-effective. The invention is furthermore based on the objective of specifying a simple, reliable, and as far as possible cost-effective method for connecting components, in particular air-conducting components.
The component according to the invention comprises a tubular main body, in particular for conducting gas, preferably air, and a connection element for connecting in a form-fitting manner to a further (second) component, said connection element being created and/or capable of being created integrally (as one piece) with the tubular main body.
The component according to the invention is in particular a component for guiding an element, in particular a gas, in particular air. The component is preferably an air-conducting component, an air conduit, or an air duct, in particular for a heating, ventilation and/or air-conditioning installation of a vehicle. In general, an air-conducting component is to be understood as a component which is suitable and provided for conducting or guiding, respectively, air from a first region to a second region. Apart from a pipe, this herein can also be a distributor housing, an intake duct, a silencer, a pipe connector, or else another component that is suitable for guiding air. In principle, however, the invention can also be applied to other components for guiding an element, for example to a cable conduit or a cable duct, for example.
A basic concept of the invention in the case of such a component for guiding an element is for a connection element (a connection portion) to be created, in particular formed, integrally with the tubular main body such that separate assembly elements can be dispensed with. The connection element and at least part of the tubular main body are thus formed on a common piece or part, respectively, or interconnected in a form-fitting manner. The connection element is thus expediently created integrally or unreleasably, respectively, with the tubular main body, on account of which the reliability of linking the component to a further component is enhanced. Moreover, additional costs on account of additional components (assembly elements) are dispensed with.
In principle, the air-guiding component according to the invention can be an arbitrary component which is provided for guiding air, in particular in a heating, ventilation and/or air-conditioning installation of a vehicle. For example, this can also be a so-called end piece, for example an adapter frame, a push-fit part, a distributor housing, or a contact pressure part, which is to be linked to an air duct. Components of this type likewise have a tubular main body for guiding gas or air, respectively. The invention enables in particular the connection of foam ducts or of ducts from other preferably elastic materials to one another so as to form nozzles and connector pieces.
The connection element, or the connection region, respectively, is preferably disposed on a circumferential face of the tubular main body, in particular on an internal circumferential face or skin surface and/or on an external circumferential face or skin surface. For a tight or leakage-free connection, respectively, to the adjacent component it is advantageously provided that the connection element is suitable for performing an elastic movement in a radial direction of the component so as to press against the component to be linked in the radial direction (toward the inside or the outside). To this end, the connection element is preferably created from an elastic material. The connection element, or the connection region (a portion of the component/air guide that is turned over), respectively, preferably offers a retention function.
In one preferred design embodiment of the invention it is provided that the connection element is produced and/or is capable of being produced by forming the tubular main body. The connection element is thus created or formed in that the tubular main body in an initial or basic state is formed. The tubular main body in the initial or basic state (prior to forming) can also be referred to as a tubular initial body. By forming, the tubular main body and the connection element that is created integrally with the former is produced or formed, respectively, from said tubular initial body. In order for the connection element to be produced, it is provided in particular for an axial end region of the tubular initial body, or of the main body, respectively, to be formed.
It is preferable for the tubular initial body (main body in an initial or basic state) in an axial end region to have a forming portion that is capable of being manually formed and is capable of being formed to create the connection element. The tubular initial body is thus capable of being formed in such a manner that the connection element can be created by the forming. It is provided in a first variant that the forming portion for creating the connection element is capable of being formed or bent in an outward manner. On account thereof, the connection element is crated on an external circumferential face, or on an external circumferential region, respectively. The component according to the invention can thus be plug-fitted into a further component. In order for a form-fitting connection to be created, the connection element engages with an engagement element of the second component. It is provided in a second variant that the forming portion for creating the connection element is capable of being formed or bent in an inward manner. This enables the second component to be plug-fitted into the component according to the invention in such a manner that a form-fitting connection is capable of being produced by an engagement of the connection element in an engagement region of the second component. In principle, it can also be provided that the tubular initial body, or the forming portion, respectively, is capable of being selectively formed in an outward or inward manner. Connecting the two components is thus preferably performed by a plug-fit in the axial direction.
In a further preferred embodiment it is provided that the connection element is produced and/or capable of being produced by turning over an axial end region, or end portion, of the tubular main body, or of the initial body, respectively. Turning over is to be understood in particular as forming or bending the axial end of the tubular initial body in a rearward or opposite direction, that is to say by more than 90°, preferably at least 135°. It is provided in particular for the axial end region of the tubular main body or initial body, respectively, to be folded or bent, respectively, in the direction of the opposite axial end. The tubular initial body is preferably turned over along a defined forming line. Turning over/folding back/folding can be performed in an outward and/or inward manner.
A good sealing effect can be achieved in that the tubular initial body, or the tubular main body, respectively, having the connection element is created from an elastic material. The elastic material enables radial sealing, in particular in a manner analogous to that of a radial shaft sealing ring. In a further preferred design embodiment it is provided that the connection element is connected to the tubular main body in an elastic-resilient manner. An articulation or a hinge which guarantees an elastic-resilient movement of the connection element relative to the tubular main body is thus preferably created between the tubular main body and the connection element.
According to the invention it is particularly preferable for the tubular main body, and correspondingly also for the connection element that is created integrally with the former, to be created from a foamed material. In one exemplary embodiment, the component according to the invention is an air guide, or an air duct, respectively, from a foam film, or is a foam film air duct, respectively. This is preferably a polyolefin foam material (PO foam material), for example PE foam material or PP foam material. The foamed material is particularly suitable for in particular manual forming, in particular at the assembly site, in order for the connection element to be produced. Moreover, good sealing can be achieved by virtue of the material properties. Finally, the foamed material is particularly light and acts in a noise-silencing and/or noise-damping manner. This is preferably a closed cell-foam material. The density is preferably in the range from 70 to 110 g/dm3, in particular 80 to 100 g/dm3, preferably of approximately 90 g/dm3.
In order for air-guiding components to be connected, it is preferable for the connection element to be suitable for establishing a sealed state in relation to the further (second) component. A sealed state herein is to be understood in particular to be a state which provides adequate sealing (in particular a tightness according to the testing rules of automotive manufacturers, for example the TL and VW testing requirements) for an air-guiding component of a vehicle heating, vehicle ventilation, and/or vehicle air-conditioning.
In order for the forming to be facilitated, it is preferable according to the invention that the tubular main body in a basic state (thus the tubular initial body) has an at least partially encircling weakening, in particular a material weakening, along which the tubular main body, or initial body, respectively, is capable of being formed in order for the connection element to be created. In particular, the tubular main body can have a transition region which creates a hinge along which the tubular main body is capable of being formed in order for the connection element to be created. The material weakening can have in particular a perforation and/or a wall thickness reduction. The material weakening is preferably created by at least one in particular encircling or interrupted cut, in particular at least one incision and/or clean cut, a serrated knife cut, or a serrated material thinning, respectively, and/or by a material thinning or a wall thickness reduction, respectively, and/or by punched features and/or cleanly punched out features, in particular in order for a perforation to be created in particular in the circumferential direction, and/or by a weakening caused by thermal means. A weakening caused by thermal means can preferably be achieved by laser machining, machining by a hot wire or a hot mandrel (similar to a soldering iron). The weakening can also be created by a bellows. On account of the weakening, the tubular initial body is subdivided into the tubular main body and a forming portion. The weakening is preferably located in an end region of the tubular initial body. The spacing of the weakening from the axial end is preferably at maximum 50 mm, particularly preferably at maximum 15 mm, or at maximum 10 mm. Said spacing is preferably at least 5 mm, in particular at least 10 mm. It is provided in particular that the spacing is between 5 and 15 mm. The spacing of the weakening from the axial end defines the axial length of the forming portion, or of the connection element to be created, respectively. In other words, the axial length of the forming portion is preferably 5 and 40 mm. The longer the portion (forming portion, or connection element, respectively), the more reliably the terminal position is maintained. The weakening preferably creates a transition portion between the main body and the forming portion or the connection element, respectively. A bellows which creates a flexible moving element can be provided as a transition portion, for example.
The length of the forming portion, or the spacing of the material weakening from the axial end of the tubular main body (in the non-formed basic state) is preferably at least two times, in particular at least three times, the material thickness of the tubular main body. Furthermore preferably, the length of the forming portion, or the spacing of the material weakening from the axial end of the tubular main body (in the non-formed state) is at maximum 10 times, in particular at maximum six times, the material thickness of the tubular main body.
The tubular main body (or the air duct, respectively) can be configured as a monocoque body. Alternatively, the tubular main body (or the air duct, respectively) is preferably created from at least two interconnected shells, preferably clamshells, or has at least two shells/clamshells, respectively. The clamshells can be produced by vacuum forming, embossing, by the FPFT (fusion press form technology), or by the twinsheet method. One particular aspect of the invention lies in an air duct, in particular from a foamed material, which is created by vacuum-formed, embossed, or FPFT-produced clamshells, or is produced by the twinsheet method, wherein the material weakening preferably is, or has been, respectively, incorporated during the production process of the clamshells. In principle, the component according to the invention can also be an injection-molded or blow-molded component, in particular having a foam structure.
In order for a potential for folding over or turning over to be produced, or for the material weakening to be produced, respectively, there are in particular the following possibilities:
In order for a potential for turning over to be produced, the main body can be embossed, or have been embossed (for example with round or wedge-shaped embossings). A hinge can be produced in particular herein.
Other geometric adaptations of the main body can be performed. For example, the main body can have a bellows which guarantees the turning-inside-out capability. The bellows creates a flexible moving element, optionally in addition to a further material weakening.
The main body can have punched features or cleanly punched-out features. Punched features or cleanly punched-out features can be incorporated in the main body.
It is possible in particular in the case of vacuum-formed, embossed, or FPFT-produced clamshells, for at least one insert part which is inserted into the main body to be provided in order for a turning-inside-out capability of the main body to be created. The at least one insert part can be at least partially covered.
In particular in the case of parts which are produced by the twinsheet method, turning over in the vacuum forming procedure can be achieved by driving in a core.
In principle, it is also conceivable for the connection element to be subsequently connected in a materially integral manner to the tubular main body, for example by welding and/or adhesively bonding the connection element, for example by welding and/or adhesively bonding a lip, in particular to a completed duct or air duct, respectively.
It is provided that the connection element is brought to engage with an engagement region or element of the further component in order for a form-fitting connection to be produced. The engagement region or element can be a depression or an elevation of the component, for example. For example, the connection element can engage in a clearance in the further component and/or engage behind a protrusion that is created on the further component. The connection element is preferably configured for creating a latching connection which is enabled in that the connection element is mounted on the tubular main body in an elastic-resilient manner. The connection element can thus pass through an engagement element of the other component, in particular in the axial direction of the tubular main body, and subsequently establish the engaged state by a radial rebound movement. The engagement region, or the engagement element, respectively, can be a latching element or a latching hook.
In order to achieve an enhanced sealing effect, it is preferable for the connection element in a longitudinal section (section along the longitudinal axis of the tubular main body) to have a curved and/or angular and/or inclined shape. On account thereof, improved wedging with an engagement element of the second component, for example a latching element or a latching hook, can take place. Moreover, improved sealing can be achieved by an acute-angled contour at the axial end of the connection element. In particular, the connection element, proceeding from a transition section at the transition between the main body and the connection element, extends in the direction of the opposite axial end of the main body, wherein an angular feature or curvature, respectively, that leads away from the main body in this direction is present.
The connection element preferably creates a lip seal for pressing radially against the second component. To this end, the connection element is preferably created from a flexible and/or elastic and/or restorable material. In particular, said connection element is capable of being pushed against the tubular main body counter to a tension force. A tension force thus preferably pushes the connection element away from the tubular main body. The seal lip is preferably created by an edge of the connection element that pushes radially against the second component.
It is preferable for the component to have a plurality of connection elements. In other words, a connection portion that is created by a plurality of connection elements can be present. The multiplicity of connection elements can be created in the form of circumferentially disposed and expediently circumferentially spaced apart lugs. A multiple-part portion that is turned over, or a multi-part connection element can be created. Part-regions along the circumference herein can also be reserved such that the individual (separate) connection elements are circumferentially spaced apart. The individual (separate) connection elements can be disposed in particular along the circumference of the component, or of the tubular main body, respectively. Non-destructive disassembling can be achieved on account of the plurality of connection elements, or notches and/or cut-outs and/or incisions and/or a material taper in the connection element/turned-over periphery. A congruence of the connection element (turned-over periphery) and of the counter element (engagement region, latching element, latching hook) can be disengaged by rotating the second component (assembly part) to be linked. Recesses in the connection element are particularly preferred in order for a latching to be unlocked.
The invention furthermore relates to an assembly of components, wherein a first component is configured according to the invention, and wherein the first component is connected and/or capable of being connected in a form-fitting manner to a second component.
The second component along at least part of the circumference thereof can have a latching element, in particular a latching cam, by way of which the connection element of the first component is connected and/or capable of being connected in a form-fitting manner. It can be provided in particular that the connection element engages behind the latching element of the second component. The latching element on the second component can be created, for example, by a partial material accumulation (creation of a bead, of a barb, etc.), by plasticization, and/or displacement.
In particular in order for two tubular air-guiding components to be connected, it is preferable for both components to be configured according to the invention. It is in particular provided herein that both components have a connection element that is created and/or capable of being created integrally with a tubular main body in order to be connected in a form-fitting manner to the respective other component. In particular, the two components can have connection regions or elements of substantially the same type, in particular connection regions or elements that are created by bending over a tubular initial body. Preferably, the connection element of a first component is created by bending over the tubular initial body outward, and the connection element of a second component is created by bending over the tubular main body inward. The connection elements of the two components are preferably interconnectable by creating a latching connection.
In a further preferred design embodiment, it is provided that the first component is releasably connected and/or capable of being releasably connected to the second component. Both components can therefore be disassembled. Disassembling can be performed in particular without releasing and/or removing a separate connection element, for example in that the components are first rotated in relation to one another and are then axially spaced apart from one another. To this end, clearances are preferably provided in the connection element, or in the turned-over periphery of the first component, as has already been explained in more detail above.
In a further aspect, the invention relates to a method for connecting components, wherein a first component has a tubular main body, in particular for guiding gas, preferably air, wherein a connection element is created integrally with the tubular main body by forming an axial end region of the tubular main body, and wherein a second component is connected in a form-fitting manner to the first component in that the connection element is brought to engage with an engagement element of the second component.
The invention overall also comprises the following aspects in particular:
The end region of an air guide is turned over. This defined turning over is enabled by an encircling or segment-type incision, or by a wall thickness reduction. The turned-over portion in the assembly process, conjointly with a push-fitted or plug-fitted adjacent component, then creates a form-fitting connection, in particular according to the barb principle. The assembly part (second component) to be linked is preferably provided with latching hooks. No separate adaptation parts are thus required for connecting the components. The air guide (the initial body) in the end region is weakened in an encircling or segment-type manner, for example by cutting, embossing, laser machining, or tapering. This can be performed during or after the production of the air guide. In the case of multiple-part air guides (for example, air guides having two clamshells), weakening is preferably performed only after welding or extruding, respectively. Turning over in a defined manner is enabled on account thereof.
The following features of the invention are to be highlighted in particular:
1. weakening (partial or encircling) in the end region of the air guide;
2. turning over the portion; and
3. fixing according to the barb principle.
The sequential or encircling cut can be produced in particular by cutting (encircling blade-cutting, kiss-cutting, laser cutting, laser using a counter sensor, cutter with anvil/device, pinching, manual work, serrated knife).
The cuts/incisions can be designed so as to be of dissimilar depth. Other possibilities for weakening are, for example, heat embossing (thermal depression by heat treatment/heat stress), a cut or cuts parallel with the actual end region of the component (trimming/punching). Furthermore, a material weakening can be provided by milled features, punched features, and cleanly punched features. In the case of multiple-shell welded air guides it is preferable for the incision region to be likewise trimmed. The plane of the weakening does not have to be perpendicular to the air guide axis.
As an alternative to turning over, it is also possible for the end region to be turned outward. In this case, it is preferable for the internal side of the air guide to have a trimmed feature or a taper, respectively.
The material thickness or wall thickness, respectively, of the tubular initial body is preferably between approximately 3 and 8 mm, in particular 4 to 6 mm, in particular approximately 5 mm. The cross section of the tubular main body is preferably between 20 and 100 mm. One exemplary embodiment provides a non-circular cross section having a first diameter of approx. 50 mm and a second diameter of approx. 70 mm.
The invention enables in particular the connection of air guides to one another or to further air-guiding components, in particular from the same material, without any additional connection elements and without additional sealing elements.
A simple, tight, and process-reliable plug-fit of an air guide (in particular from foam film, or a foamed air guide, or a blow-molded part, respectively) to a periphery (for example a vent, a distributor housing, an adapter frame, or a neighboring air guide) having a sufficiently firm fit is enabled by the invention.
The invention offers the following advantages in particular:
an integral air guide;
no additional adapters, or additional process steps, respectively;
a firm fit;
the production of the component according to the invention can be integrated in the manufacturing process of an air guide;
the connection of two components takes places according to a tested blocking principle (latching hook/barb);
simple fixing in relation to neighboring components is enabled;
the connection is very tight, in particular similar to a radial shaft seal ring.
There is no leakage worth mentioning. The tightness can be even enhanced by an inclined lip shape, or by an inclined connection element, respectively);
the invention can also be applied to non-concentric cross-sectional shapes;
the doubling of the wall thickness by turning over offers an enhanced peripheral rigidity.
The invention will be described in more detail hereunder by means of preferred exemplary embodiments which are illustrated in the appended schematic figures in which:
Same elements, or elements of equivalent function, are identified by the same reference signs in all figures.
A production process of a component 10 according to the invention is illustrated in
The initial body 20 at one axial end region has an encircling (continuous or interrupted) material weakening 22 which subdivides the tubular initial body 20 into a base portion 24 and a forming portion 26. For example, the material weakening 22 can be created by an encircling incision, for example in an external face of the initial body 20.
The forming portion 26 in the embodiment illustrated is folded over inward. However, folding over or folding over outward is also possible in principle. The welded periphery 34 is trimmed in the region of the forming portion 26. In other words, the welded periphery 34 in the region of the forming portion 26 can have been removed at least partially, preferably completely. Despite the welded periphery 34 present, this enables the turning over, or the folding over, respectively, of the forming portion 26 in the case of an initial body 20 that is created from two clamshells 30, 32.
A component 10 according to the invention and the form-fitting connection thereof to a second component 100 are illustrated in
In principle, the tubular initial body 20 can have an arbitrary cross-sectional shape, for example an angular, round, circular, elliptic, polygonal shape, or any combination thereof.
The form-fitting connection of the component 10 to a second component 100 is illustrated in
The latching element 106 in
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2015 109 090.2 | Jun 2015 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/062866 | 6/7/2016 | WO | 00 |
