U-Shaped Air Diffuser Brace for Rigid Disc Support
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Solution Overview
Problem
Conventional air diffusers with a brace made from the same material blank as the diffuser body part face challenges in achieving sufficient rigidity to support the flow control disc without increasing fabrication complexity or impeding air flow and noise generation, especially in larger designs.
Innovation Solution
The brace is bent into a U-shaped cross section with affixed flanges at multiple points, either by welding, riveting, or crimping, to enhance rigidity and support the flow control disc, while maintaining the same material blank and minimizing air flow obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brace is made from the same material blank as the diffuser body part, then fabrication complexity is reduced, but the brace rigidity is insufficient to support the flow control disc
Solution Approach 1:
The brace cross-section is segmented into two flanges that are affixed to each other at multiple points, creating a composite structure that enhances rigidity while maintaining integration with the body part
Solution Approach 2:
The brace utilizes a composite cross-sectional structure with two flanges affixed together, creating a composite form from the same material that provides enhanced mechanical properties and rigidity
2Strength
If three radial legs are used in the brace design, then the brace rigidity is sufficiently high, but air flow is impeded and noise generation increases
Solution Approach 1:
The brace transitions from a planar design to a three-dimensional U-shaped cross-section with affixed flanges, achieving enhanced rigidity through dimensional complexity rather than adding more radial legs that would obstruct air flow
3Strength
If the flanges of the brace cross section are affixed at multiple points, then the brace rigidity is substantially increased, but manufacturing complexity increases
Solution Approach 1:
The affixing process is merged into the single-step bending operation, combining multiple functions (forming and affixing) into one manufacturing process that does not increase overall complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly increases the brace's rigidity to effectively support the flow control disc, particularly in larger diffusers, without the drawbacks of additional complexity or noise and air flow issues present in prior art techniques.
Implementation Method 1
A preferred embodiment of the invention is characterized in that the flanges of the brace cross section are affixed to each other by welding.
Implementation Method 2
A second preferred embodiment of the invention is characterized in that the flanges of the brace cross section are affixed to each other by rivets.
Implementation Method 3
A further preferred embodiment of the invention is characterized in that the flanges of the brace cross section are affixed to each other using a crimping technique.
Data Source
Figure 1~3
Figure 4~5
AI summary
An air diffuser is disclosed comprising a body part (1) with an air flow channel passing there through and a brace (2) for supporting a flow control disc, the brace having an elongated shape extending across the cross section of the flow channel and the brace (2) being made from the same material blank as the body part (1) and the center point of the brace having an inner-threaded hole (3) made thereon to accommodate the center shaft of the flow control disc. The invention is implemented such that the brace (2) is bent into a substantially U-shaped cross section and the flanges of the brace cross section are affixed to each other at least at one point about either side of the brace center hole (3).