Method of making an inline housing for a part enclosed in a tube

Abstract

A method is disclosed for making a duct assembly including an internal component part such as a silencer is disclosed. The duct assembly may be made in a blow-molding operation in which first and second duct parts are formed from a single parison as a combined part that is then split apart to receive a component part in a housing and subsequently closed by a closure part. Alternatively, the first and second housing parts may be separately formed and a component part may be inserted into a housing defined by one or both of the first and second duct parts. The first and second duct parts may be joined and sealed by injection molding a ring over telescopically assembled ends of the first and second parts.

What is claimed is: 
     
         1 . A duct assembly comprising:
 a first duct including a first length of tubing and a housing integrally formed with the first length of tubing;   a second duct including a second length of tubing and a closure member integrally formed with the second length of tubing;   a component part disposed in the housing; and   a joint connecting the housing to the closure member to seal the component part inside the housing.   
     
     
         2 . The duct assembly of  claim 1  wherein the joint further comprises:
 a first telescopic portion of the housing; 
 a second telescopic portion of the closure member telescopically assembled onto the first telescopic portion; and 
 a continuous ring molded over the first telescopic portion and the second telescopic portion for joining and sealing the joint the housing and the closure member. 
 
     
     
         3 . The duct assembly of  claim 1  wherein at least one of the first and second lengths of tubing are made of a thermoplastic polymer that is molded to a non-cylindrical shape. 
     
     
         4 . The duct assembly of  claim 1  wherein the component part is a silencer formed of an energy absorbing material. 
     
     
         5 . The duct assembly of  claim 4  wherein the energy absorbing material is fiberglass retained in a cylindrical retainer defining a plurality of circumferentially and axially spaced openings.