Pliable-Wall Air Duct with Internal Expansion to Prevent Sagging
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Solution Overview
Problem
Metal air ducts in warehouse and manufacturing environments face issues such as condensation leading to mold and bacteria growth, uncomfortable drafts, and unsightly sagging when deflated, along with noise from sudden inflation.
Innovation Solution
The implementation of a pliable-wall air duct system with an internal framework that maintains the duct in a taut, expanded shape using a central shaft and radial spokes, preventing buckling and ensuring consistent airflow and appearance, regardless of pressure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fabric duct is used instead of metal duct, then condensation and mold problems are reduced, but the duct sags when deflated and creates noise during inflation
Solution Approach 1:
The patent uses a fabric duct with a flexible porous wall that allows the duct to be lightweight and resistant to condensation, while incorporating an internal framework to maintain shape when deflated
Solution Approach 2:
The internal framework is divided into multiple radial support members spaced along the duct length, with circumferential clamps securing them to the fabric wall, creating a segmented support structure that prevents sagging
2Ease of operation
If a fabric duct is used instead of metal duct, then air distribution is improved, but the duct produces loud popping sounds during inflation
Solution Approach 1:
The flexible fabric wall allows gradual inflation without the sudden snapping sound associated with rigid structures, while the internal framework provides gradual support as air pressure builds
Solution Approach 2:
The internal framework is pre-installed within the fabric duct before inflation, providing gradual structural support that cushions against sudden fabric tensioning and prevents popping sounds during the inflation process
3Shape
If an internal framework is added to maintain duct shape, then duct appearance and airflow consistency are improved, but device complexity increases
Solution Approach 1:
The fabric duct itself serves as the primary structural element, requiring only a relatively simple internal framework rather than a complex rigid structure, thereby maintaining shape while minimizing added complexity
Solution Approach 2:
The framework is segmented into discrete radial support members spaced along the duct, each independently clamped to the fabric wall, simplifying installation and reducing overall structural complexity while effectively preventing sagging
Data Source
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AI summary
Pliable-wall air ducts with internal expanding structures are disclosed. An example air duct system includes a shaft to be disposed within an air duct, to extend in a longitudinal direction, and to be in longitudinal compression. The air duct system also includes a plurality of ribs to be coupled to the shaft and to engage an inner surface of the air duct and a spring to be disposed within the air duct, the spring to be coupled to the shaft. The spring under stress being a contributing factor in both the shaft being in longitudinal compression and the air duct being in longitudinal tension. A method of retrofitting an existing air duct system with internal expanding structure is also disclosed.