Adjustable start collar
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Solution Overview
Problem
HVAC installers face challenges in customizing ductwork for varying airflow needs due to the need for multiple, non-adjustable start collars of different diameters, leading to increased costs and inefficiencies in carrying and storing spare parts.
Innovation Solution
An adjustable start collar with a base having multiple slots and foldable tabs, allowing it to be easily converted between different diameters by positioning the flange in various slots, enabling it to fit multiple duct sizes and reducing the need for multiple parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple fixed-diameter start collars are manufactured for different airflow needs, then each specific diameter can be precisely fitted, but the device complexity and inventory requirements increase
Solution Approach 1:
The start collar is designed with multiple slots at different positions on the curved base, allowing a single collar to serve multiple functions by fitting different duct diameters. The flange can be positioned in different slots depending on the required duct size, making one collar universal for various airflow needs.
Solution Approach 2:
The base of the start collar is segmented with multiple slots positioned at different locations. This segmentation allows the flange to be attached at different positions, creating variable effective diameters from a single collar structure.
2Reliability
If installers carry multiple spare start collars of different sizes, then the correct part is available on-site, but the loss of substance and storage requirements increase
Solution Approach 1:
Instead of carrying multiple specialized collars, the installer carries one universal adjustable collar that can be configured for different duct sizes by positioning the flange in appropriate slots, eliminating the need for multiple spare parts.
Solution Approach 2:
Multiple fixed-diameter collar designs are merged into a single adjustable collar design. The various diameter options are combined into one structure through the slot system, allowing the installer to have all sizes in one part.
3Manufacturing precision
If multiple fixed-diameter start collars are manufactured, then each collar is optimized for its specific application, but the manufacturing cost and time increase
Solution Approach 1:
The manufacturing process produces one universal collar design that can serve multiple applications. Instead of manufacturing several different fixed-diameter collars, a single collar type with multiple slot positions is produced, streamlining production while maintaining application-specific fit through slot selection.
Solution Approach 2:
The collar transitions from a static fixed-diameter design to a dynamic adjustable design. The flange can be repositioned between different slots to change the effective diameter, allowing the same manufactured part to adapt to different applications without requiring multiple manufacturing runs.
Data Source
AI summary
An adjustable duct start collar may include a base with a flange on a first end of the base and a plurality of tabs on a second end of the base. The base may be constructed of a material of substantially uniform thickness and include at least two slots in the base. The first of the slots may be positioned substantially parallel to a second of the at least two slots. Each of the slots of the at least two slots being able to independently receive the flange, whereby when the base is curved into a cylindrical shape with the flange positioned in the first of at least two slots, the curved base will form a cylindrical shape with a first diameter and when the flange is positioned in the second of the at least two slots, the curved base will form a cylindrical shape with a second diameter.