Access panel and diffuser installation
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Solution Overview
Problem
Existing methods for installing ceiling access panels and diffusers in air conditioning and air circulating systems often result in air being directed downwards, causing discomfort to occupants and require complex procedures for secure attachment to ceiling studs.
Innovation Solution
A method involving a frame with a base and outer perimeter portion, a metal flange placed between a ceiling stud and gypsum board, and fasteners to securely attach the gypsum board to the ceiling stud, allowing for efficient installation of access panels or diffusers while creating an opening in the gypsum board for seamless integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing installation methods are used, then the attachment process becomes complex, but the security of attachment to ceiling studs is compromised
Solution Approach 1:
The patent introduces a metal flange as an intermediary component between the gypsum board and the ceiling stud. The flange includes a stud-receiving portion that engages with the ceiling stud and a board-receiving portion that attaches to the gypsum board, thereby simplifying the overall attachment process while ensuring secure connection.
Solution Approach 2:
The attachment system is divided into distinct segments: the metal flange with its stud-receiving portion and board-receiving portion, the gypsum board with pre-formed opening, and the ceiling stud. This segmentation allows each component to perform its specific function independently, simplifying installation while maintaining security.
2Ease of operation
If diffusers are installed without proper framing, then installation is simpler, but air flow direction cannot be controlled causing discomfort to occupants
Solution Approach 1:
The gypsum board is provided with a pre-formed opening before attachment to the ceiling stud. This preliminary action allows the diffuser to be properly positioned and framed during installation, ensuring correct air flow direction (radially outward and horizontally along the ceiling) while maintaining installation simplicity.
Data Source
AI summary
A method includes providing a diffuser that has a frame with a base portion and an outer perimeter portion that protrudes outwards from the base portion. The outer perimeter portion includes a metal flange. A portion of the metal flange is attached to a ceiling stud of a ceiling. The method includes forming an opening in a gypsum board to accommodate the diffuser, and assembling the gypsum board with the ceiling stud so that a bottom surface of the frame of the diffuser is flush with the gypsum board.