Circular Duct Snap Lock Sealing With Integrated Foam Sealant

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Solution Overview

Problem

Existing circular duct systems with self-locking mechanisms leak due to the incompatibility of liquid sealants with manufacturing processes, leading to inefficiency and additional cleaning requirements, and there is no known solution for sealed circular ducts with self-locking mechanisms.

Innovation Solution

A sheet metal duct with a built-in foam sealant integrated into the interlocking mechanism, allowing for seamless assembly and reassembly without external sealing materials, using a forming machine to create a snap lock mechanism with the sealant inserted between specific rolls, ensuring a tight seal without leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If liquid sealant is applied to circular duct work with self locking mechanism, then sealing is attempted, but the liquid sealant flows or strings outside of the applied area onto the forming rolls causing machinery malfunction

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing process compatibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the physical state of the sealant from liquid to foam form. The foam sealant is applied as a expanding foam that cures in place, preventing it from flowing onto forming rolls while still providing effective sealing at the duct joint interfaces

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The foam sealant is applied as a disposable material that expands and cures to fill the joint space, eliminating the need for precise application control required by liquid sealants and preventing contamination of manufacturing equipment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If liquid sealant is used with circular duct work, then sealing is achieved, but excess liquid sealant adheres to interior and exterior of duct creating dirt collection points and cleaning requirements

Engineering Contradiction:

Improvesealing effectivenessVSAvoiddust collection and air quality hazards

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Changing from liquid to foam sealant eliminates excess material that would otherwise adhere to duct surfaces. The foam expands to fill only the joint space and cures in place, preventing creation of dirt collection points on duct interiors and exteriors

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The expanding foam property that could be seen as messy is converted into a benefit by filling irregular joint spaces completely and curing to a clean, dust-free finish that doesn't create air quality hazards

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If liquid sealant is applied to circular duct with self locking mechanism, then sealing is attempted, but when self locking mechanism is disengaged for cutting, the integrity of the sealant is compromised causing failure to seal when re-engaged

Engineering Contradiction:

Improvesealing integrityVSAvoidreusability of self locking mechanism

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The foam sealant cures to a flexible but durable state that maintains seal integrity even when the self-locking mechanism is disengaged and re-engaged multiple times, unlike liquid sealant that loses integrity upon disruption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The foam sealant is applied beforehand to create a cushioning seal that accommodates subsequent disengagement and reengagement of the locking mechanism without compromising sealing integrity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If liquid sealant is used on circular duct work, then sealing is achieved, but the sealant off gasses VOCs into the air

Engineering Contradiction:

Improvesealing effectivenessVSAvoidVOC emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Changing from liquid to foam sealant formulation reduces or eliminates VOC emissions while maintaining sealing effectiveness, addressing both environmental concerns and indoor air quality requirements

Inventive Principle:

Principle #35Parameter changes

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 sealed duct system directly from the manufacturer, reducing energy consumption and eliminating the need for additional sealing materials, while maintaining air quality and preventing mold growth, with minimal leakage rates even under high pressures.

Implementation Method 1

A sheet metal duct with a built-in foam sealant integrated into the interlocking mechanism

Methodology Applied

Scientific EffectFoam expansion: Foam

Implementation Method 2

A sheet metal duct with a built-in foam sealant integrated into the interlocking mechanism

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 3

using a forming machine to create a snap lock mechanism

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS8505185B2Method of installing sealed circular ductwork

Publication Date: 2013.08.13 DMI CO INC

AI summary

A circular sheet metal duct having a sealant applied across the longitudinal seam. The sealant will improve the efficiency and will reduce or eliminate air leakage from the longitudinal seam. The sealant is applied during the manufacturing processes so that an installer does not have to seal the duct work. The method of manufacturing the sealant is provided.