Bowed Duct Flange Corner Connector for Fast Leak-Resistant Assembly
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Solution Overview
Problem
Existing corner flange connection methods for duct assemblies in HVAC systems often result in insecure connections, allowing adjacent flanges to move independently, leading to leaks and requiring additional time for reattachment, and do not effectively accommodate manufacturing defects or misalignment.
Innovation Solution
The development of a high-speed corner flange connection member with a bowed configuration that applies increased clamping force through integrally formed leg portions and specialized fasteners, eliminating the need for conventional bolts and washers, and allowing for easy installation and alignment using automated machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional corner flange connectors with single bolts and washers are used, then the connection can be made with simple components, but the connection becomes insecure allowing flanges to move independently
Solution Approach 1:
The corner flange connector employs a bowed configuration where the leg portions are curved rather than straight. This curvature allows the connector to flex and apply continuous clamping force to the duct flanges, creating a more secure connection that prevents independent movement of adjacent flanges while maintaining structural integrity.
Solution Approach 2:
The invention changes the geometric parameters of the connector by introducing bows or curves in the leg portions. This parameter change transforms the rigid straight connector into a flexible bowed connector that can accommodate flange movement and maintain clamping force, thereby improving connection strength without significantly increasing complexity.
2Reliability
If corner flange connectors are designed for secure connection, then leakage is reduced, but installation time increases due to additional fastening steps
Solution Approach 1:
The corner flange connector integrates multiple functions into a single component: the bowed leg portions provide both the structural connection elements and the clamping force application mechanism. This merging eliminates the need for separate clips or additional fastening steps, achieving reliable sealing while maintaining efficient installation.
Solution Approach 2:
The bowed configuration of the connector enables it to self-adjust and self-clamp onto the duct flanges. As the connector is installed, the elastic deformation of the bowed legs automatically generates clamping force, eliminating the need for additional adjustment or tightening operations and reducing installation time while ensuring reliable sealing.
3Adaptability or versatility
If traditional flange connection methods are used, then manufacturing simplicity is maintained, but misalignment and manufacturing defects cannot be accommodated
Solution Approach 1:
The corner flange connector transitions from a rigid static structure to a dynamic flexible structure through the bowed leg portions. This flexibility allows the connector to adapt to misalignment and manufacturing defects in the duct flanges during installation, accommodating variations without requiring precise alignment while maintaining ease of manufacture.
4Strength
If multiple clips or screws are used to hold flanges together, then connection security is improved, but device complexity and installation time increase
Solution Approach 1:
The invention merges the functions of multiple clips or screws into a single integrated corner flange connector. The bowed leg portions collectively provide the clamping force that would otherwise require multiple separate fastening components, reducing device complexity while maintaining or improving connection strength.
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
The solution provides a robust, secure, and efficient connection that reduces leakage, simplifies installation, and accommodates manufacturing defects and misalignment, while eliminating cross-threading and misalignment issues, and can be quickly completed using power tools.
Implementation Method 1
the leg portions are bowed or otherwise bent such that when the corner flange connector member is initially positioned within the duct channel flange, only portions of the corner flange connection member rest upon the duct channel flange while other portions are spaced from or elevated above the duct channel flange so as to form a spring-type biasing action
Data Source
AI summary
In one embodiment, an improved high-speed corner flange connection member is disclosed which includes creases or bends allowing the leg portions to be bent or angularly deflected away from such creases downwardly so as to form a bowed configuration. In some embodiments, the connection member includes clearance holes and tap holes which are strategically positioned such that when a pair of duct sections are positioned in end-to-end relationship for joinder, the opposed connection members are arranged such that a clearance hole is positioned in registration with a tap hole; other embodiments include similarly shaped openings which are associated with the respective opposed connection members; and in still other embodiments, a substantially flat corner element is constructed utilizing the strategically placed clearance and tap holes. A plurality of differently configured high-speed fastener members for substantially eliminating misalignment and cross-threading issues are also disclosed.