Pliable-Wall Air Duct Structure That Prevents Sagging and Popping
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Solution Overview
Problem
Metal ducts in buildings can cause condensation issues leading to mold and bacteria growth, uncomfortable drafts, and unsightly sagging when deflated, and produce noise when re-inflated, posing challenges in environments where air quality and aesthetics are critical.
Innovation Solution
A pliable-wall air duct system with an internal framework made of rigid materials like plastic or fiberglass that maintains the duct's shape and tension, preventing sagging and noise when the air supply is off, and ensuring even airflow distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal ducts are used, then structural strength and durability are improved, but condensation formation and mold/bacteria growth occur due to thermal conductivity
Solution Approach 1:
The patent replaces rigid metal ducts with flexible fabric ducts that have lower thermal conductivity, preventing condensation formation on the duct surface. The fabric material acts as a thermal insulator while maintaining structural integrity through internal support structures.
Solution Approach 2:
The invention uses composite construction combining fabric outer layer with internal rigid support structures (such as metal or plastic ribs). This composite approach provides both the thermal insulation properties of fabric and the structural strength of rigid materials, resolving the contradiction between strength and condensation prevention.
2Object-affected harmful factors
If fabric ducts are used, then condensation and mold growth are prevented due to lower thermal conductivity, but the duct sags and creates aesthetic issues when air pressure is reduced
Solution Approach 1:
The fabric duct is divided into multiple segments by internal rigid support structures (ribs or rings) spaced along its length. These segments maintain their shape independently, preventing the entire duct from sagging when air pressure decreases, while still allowing the fabric to provide thermal insulation.
Solution Approach 2:
Internal rigid support structures serve as intermediaries between the fabric surface and the air pressure. These supports maintain the duct's external shape and prevent sagging, while the fabric layer continues to provide thermal insulation and condensation prevention.
3Ease of operation
If fabric ducts are used, then airflow is evenly distributed through porosity, but loud popping noise occurs when the duct re-inflates after deflation
Solution Approach 1:
The internal rigid support structures are pre-installed within the fabric duct before operation. These supports maintain the duct's expanded shape even when air pressure is reduced, preventing the fabric from collapsing and eliminating the popping noise that occurs during re-inflation, while still allowing controlled airflow through the fabric porosity.
Data Source
AI summary
Example air ducts comprising pliable tubular sidewalls are provided with example internal frameworks that hold the duct in a generally expanded shape even when the duct is depressurized. The framework tensions the pliable sidewall material along the length of the ducts to keep the material taut. In some examples, the framework is restrained within the duct such that the duct's sidewall, being in tension, holds the framework in compression longitudinally. Thus, in the longitudinal direction, the duct is in tension and the framework is in compression. To prevent the framework from buckling under the compressive force, some example frameworks comprise a central longitudinal shaft with a plurality of radial spokes and rings that help hold the shaft straight. In some examples, the rings also help hold the duct radially expanded.