Air Handling Unit Panel With Insulated Interlocking Joints

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Solution Overview

Problem

Air handling unit panels face challenges in alignment, thermal bridging, and structural framework issues, leading to quality concerns and increased costs due to the need for complex assembly and high production costs of metal joining elements.

Innovation Solution

A panel design featuring an outer and inner plate with a layer of insulating material and a joining element with a projecting rib and hollow groove, where the rib and groove are part of a single piece, allowing for easier alignment and reduced thermal bridging without a structural framework, and made from thermally insulating material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If metal joining elements (male and female connectors) are used to align panels, then panel alignment is improved, but production cost increases

Engineering Contradiction:

Improvepanel alignmentVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines both the male connector (protrusion) and female connector (recess) into a single joining element. This single element features a protrusion on one face and a recess on an adjacent face, eliminating the need to manufacture and assemble separate male and female connectors. The merging reduces production complexity and cost while maintaining the alignment function through the integrated geometry of the single element.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single joining element serves multiple functions: it provides both the male connector interface (via its protrusion) and the female connector interface (via its recess), enables panel alignment, and contributes to thermal insulation when made from insulating material. This multi-functionality reduces the number of different parts needed and simplifies the overall assembly process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If metal plates are tightened against each other, then structural integrity is improved, but thermal bridges are created

Engineering Contradiction:

Improvestructural integrityVSAvoidthermal leakage

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The joining element acts as an intermediary between the inner and outer metal plates. By positioning the joining element (made from thermally insulating material) between the plates, it mediates the connection while blocking thermal bridges. The insulating material in the joining element interrupts the direct thermal conduction path that would otherwise exist between the metal plates.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The joining element is made from composite or composite-like material that combines structural functionality with thermal insulation properties. This allows the joining element to provide mechanical connection while simultaneously reducing thermal conduction, addressing both structural integrity and energy loss concerns.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If a structure framework is implemented to support panels, then structural stability is improved, but unit weight and cost increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidunit weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the separate structure framework from the design. Instead of adding a framework to support the panels, the panels themselves are designed to be self-supporting through their sandwich construction (inner plate, insulating layer, outer plate) and the integrated joining elements that connect them directly. This removal of the framework reduces both weight and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The panel assembly serves its own structural support function without requiring an external framework. The joining elements with their protrusions and recesses enable the panels to interconnect and support each other, making the structure self-supporting. This self-service capability eliminates the need for additional support structures.

Inventive Principle:

Principle #25Self-service

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 ensures cost-effective alignment of panels, reduces thermal bridging, and eliminates the need for a structural framework, enhancing the quality and efficiency of air handling units while maintaining structural integrity.

Implementation Method 1

a layer of insulating material arranged between the outer plate and the inner plate

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10408491B2Panel for a module of an air handling unit

Publication Date: 2019.09.10 CARRIER CORP

AI summary

This panel (6) for a module of an air handling unit defines a main axis perpendicular to its surface and includes an outer plate (8), an inner plate (10), a layer (12) of insulating material arranged between the outer plate and the inner plate, and a joining element (14) arranged around the layer of insulating material and intercalated between the outer plate and the inner plate along the main axis. The plates and the layer of insulating material are parallel to each other and perpendicular to the main axis of the panel. The joining element includes both a male assembly part (34) formed by a projecting rib and a female assembly part (36) formed by a hollow groove and the projecting rib of the joining element is configured to nest into the hollow groove of another joining element with an identical transversal section belonging to another panel.