Air duct assembly with a secured seal

1. An air duct assembly attachable to a receiving port, comprising:

an air duct having an inner surface and an exterior surface connected to one another at a coupling fixture;

a seal connected and bonded to said coupling fixture, said seal extending axially from said coupling fixture, said seal having a tip with an inner diameter smaller than said coupling fixture's inner diameter; and

a shell connected to said coupling fixture and said seal, said shell extending axially from said seal, said shell connectable to the receiving port.

2. The assembly according to claim 1 , wherein said coupling fixture comprises a rim collar extending radially outwardly from said exterior surface, said seal encapsulating said rim collar.

3. The assembly according to claim 2 , further comprising:

an end surface connecting said exterior surface to said interior surface at said coupling fixture, said seal extending radially and axially from said exterior surface, said tip and said end surface forming a tip cavity therebetween.

4. The assembly according to claim 3 , wherein said air duct has an opening defined by said interior surface, and wherein the receiving port is partially received into said opening and deflects said tip into said tip cavity so as to seal around the receiving port.

5. The assembly according to claim 2 , wherein said coupling fixture further comprises at least one flange rib extending radially outwardly from said exterior surface, said shell encapsulating said at least one flange rib and a section of said seal.

6. The assembly according to claim 5 , wherein said coupling fixture further comprises a duct flange extending between said rim collar and said at least one flange rib, wherein said duct flange extends radially outward from said exterior surface.

7. The assembly according to claim 6 , wherein said shell extends axially and radially from said seal, said shell having lateral openings therethrough to receive a latch which detachably connects said shell to the receiving port.

8. The assembly according to claim 1 , wherein said seal is captured between said coupling fixture and said shell and extends therefrom so as to seal around the receiving port.

9. An air duct assembly for transferring air or the like from one component to another, comprising:

a receiving port having an exterior surface which has a port seal surface and a latch groove, said receiving port having a port opening;

a duct having a coupling fixture at an end thereof, said duct having a duct opening alignable with said port opening;

a seal bonded to said coupling fixture and extending axially therefrom, said seal having a tip with an inner diameter smaller than an outer diameter of said port seal surface;

a shell connected to said coupling fixture and said seal, said shell extending axially from said seal and having lateral openings therethrough; and

a latch receivable in said lateral openings which are alignable with said latch groove when said duct is positioned on to said receiving port and wherein said tip seals around said port seal surface.

10. The air duct assembly according to claim 9 , wherein said coupling fixture comprises:

at least one flange rib extending radially outward from said exterior surface; and

a rim collar extending radially outward from said exterior surface.

11. The air duct assembly according to claim 10 , wherein said seal is connected to and encapsulates said rim collar, and wherein said shell is connected to and encapsulates said at least one flange rib such that said seal is secured between said shell and said coupling fixture.

12. The air duct according to claim 11 , wherein said duct has an interior surface and an exterior surface connected to one another by an end surface, said seal extending axially and radially from said exterior surface, said tip and said end surface forming a tip cavity therebetween, wherein said tip is deflected into said tip cavity when engaged by said port seal surface.

13. The air duct according to claim 10 , wherein said coupling fixture further comprises a duct flange extending radially outward from an exterior surface of said duct, said at least one flange rib and said rim collar extending from said duct flange.

14. The air duct according to claim 9 , wherein said duct has an interior surface and an exterior surface connected to one another by an end surface, said seal extending axially and radially from said exterior surface, said tip and said end surface forming a tip cavity therebetween, wherein said tip is deflected into said tip cavity when engaged by said port seal surface.

15. A method of forming an air duct connector with a secured seal, comprising:

forming an air duct with an exterior and an interior surface connected to one another at a coupling fixture;

bonding a seal to said coupling fixture so that said seal extends axially from said coupling fixture, wherein said seal has a tip with an inner diameter smaller than a selected interior of said coupling fixture's inner diameter; and

attaching a shell to said coupling fixture and said seal, said shell extending axially from said seal.

16. The method according to claim 15 , further comprising:

overmolding said seal to said coupling fixture so as to form a mechanical and chemical bond therebetween.

17. The method according to claim 16 , further comprising:

overmolding said shell on to said seal and said shell so as to form a mechanical bond to both.

18. The method according to claim 15 , further comprising:

forming a tip cavity between said tip and said coupling fixture.